Corrosion-resistant coated copper and method for making the same

ABSTRACT

A corrosion-resistant coated base metal coated with a corrosion resistant alloy. The corrosion resistant alloy includes tin and zinc. The corrosion resistant coated base metal includes a heat created intermetallic layer primarily including copper and zinc.

[0001] This patent application is a continuation-in-part of co-pendingSer. No. 10/144,128 filed May 10, 2002, which in turn is a continuationof Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn is acontinuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/165,085 filed Dec. 10, 1993, nowU.S. Pat. No. 5,397,652, which in turn is a continuation-in-part of Ser.No. 08/000,101 filed Jan. 4, 1993, now abandoned, which in turn is acontinuation-in-part of Ser. No. 07/858,662 filed Mar. 27, 1992, nowU.S. Pat. No. 5,314,758.

[0002] This patent application is also a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/260,333 filed Jun. 15, 1994, nowU.S. Pat. No. 5,429,882, which in turn is a continuation-in-part of Ser.No. 08/209,400 filed Mar. 14, 1994, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/175,523 filed Dec. 30, 1993, nowU.S. Pat. No. 5,401,586, which in turn is a continuation-in-part of Ser.No. 08/154,376 filed Nov. 17, 1993, now abandoned, which in turn is acontinuation of Ser. No. 08/042,649 filed Apr. 5, 1993, now abandoned.

[0003] This patent application is further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/341,365 filed Nov. 17, 1994, nowU.S. Pat. No. 5,489,490, which in turn is a continuation-in-part of Ser.No. 08/175,523 filed Dec. 30, 1993, now U.S. Pat. No. 5,401,586, whichin turn is a continuation-in-part of Ser. No. 08/154,376 filed Nov. 17,1993, now abandoned, which in turn is a continuation of Ser. No.08/042,649 filed Apr. 5, 1993, now abandoned.

[0004] This patent application is still further a continuation-in-partof co-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/347,261 filed Nov. 30, 1994, nowU.S. Pat. No. 5,491,035, which in turn is a continuation-in-part of Ser.No. 08/175,523 filed Dec. 30, 1993, now U.S. Pat. No. 5,401,586, whichin turn is a continuation-in-part of Ser. No. 08/154,376 filed Nov. 17,1993, now abandoned, which in turn is a continuation of Ser. No.08/042,649 filed Apr. 5, 1993, now abandoned.

[0005] This patent application is yet further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/175,523 filed Dec. 30, 1993, nowU.S. Pat. No. 5,401,586, which in turn is a continuation-in-part of Ser.No. 08/154,376 filed Nov. 17, 1993, now abandoned, which in turn is acontinuation of Ser. No. 08/042,649 filed Apr. 5, 1993, now abandoned.

[0006] This patent application is also a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/373,533 filed Jan. 17, 1995, nowU.S. Pat. No. 5,455,122, which in turn is a continuation of Ser. No.08/254,875 filed Jun. 6, 1994, now abandoned, which in turn is adivisional of Ser. No. 08/209,400 filed Mar. 14, 1994, now abandoned,which in turn is a continuation-in-part of Ser. No. 08/175,523 filedDec. 30, 1993, now U.S. Pat. No. 5,401,586, which in turn is acontinuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993, nowabandoned, which in turn is a continuation of Ser. No. 08/042,649 filedApr. 5, 1993, now abandoned.

[0007] This patent application is further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/338,337 filed Nov. 14, 1994, nowabandoned, which in turn is a divisional of 08/229,097 filed Apr. 18,1994, now U.S. Pat. No. 5,395,702, which in turn is a continuation ofSer. No. 08/000,101 filed Jan. 4, 1993, now abandoned, which in turn isa continuation-in-part of Ser. No. 07/858,662 filed Mar. 27, 1992, nowU.S. Pat. No. 5,314,758.

[0008] This patent application is yet further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,078 filed Feb. 20, 1996, now U.S. Pat. No. 5,695,822, which inturn is a divisional of Ser. No. 08/438,042 filed May 8, 1995, now U.S.Pat. No. 5,597,656, which in turn is a continuation-in-part of Ser. No.08/338,386 filed Nov. 14, 1994, now U.S. Pat. No. 5,470,667, which inturn is a continuation of Ser. No. 08/175,523 filed Dec. 30, 1993, nowU.S. Pat. No. 5,401,586, which in turn is a continuation-in-part of Ser.No. 08/154,376 filed Nov. 17, 1993, now abandoned, which in turn is acontinuation of Ser. No. 08/042,649 filed Apr. 5, 1993, now abandoned.

[0009] This patent application is also a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,078 filed Feb. 20, 1996, now U.S. Pat. No. 5,695,822, which inturn is a divisional of Ser. No. 08/438,042 filed May 8, 1995, now U.S.Pat. No. 5,597,656, which in turn is a continuation-in-part of Ser. No.08/260,333 filed Jun. 15, 1994, now U.S. Pat. No. 5,429,882, which inturn is a continuation-in-part of Ser. No. 08/209,400 filed Mar. 14,1994, now abandoned, which in turn is a continuation-in-part of Ser. No.08/175,523 filed Dec. 30, 1993, now U.S. Pat. No. 5,401,586, which inturn is a continuation-in-part of Ser. No. 08/154,376 filed Nov. 17,1993, now abandoned, which in turn is a continuation of Ser. No.08/042,649 filed Apr. 5, 1993, now abandoned.

[0010] This patent application is further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,078 filed Feb. 20, 1996, now U.S. Pat. No. 5,695,822, which inturn is a divisional of Ser. No. 08/438,042 filed May 8, 1995, now U.S.Pat. No. 5,597,656, which in turn is a continuation-in-part of Ser. No.08/341,365 filed Nov. 17, 1994, now U.S. Pat. No. 5,489,490, which inturn is a continuation-in-part of Ser. No. 08/175,523 filed Dec. 30,1993, now U.S. Pat. No. 5,401,586, which in turn is acontinuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993, nowabandoned, which in turn is a continuation of Ser. No. 08/042,649 filedApr. 5, 1993, now abandoned.

[0011] This patent application is yet further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,078 filed Feb. 20, 1996, now U.S. Pat. No. 5,695,822, which inturn is a divisional of Ser. No. 08/438,042 filed May 8, 995, now U.S.Pat. No. 5,597,656, which in turn is a continuation-in-part of Ser. No.08/347,261 filed Nov. 30, 1994, now U.S. Pat. No. 5,491,035, which inturn is a continuation-in-part of Ser. No. 08/175,523 filed Dec. 30,1993, now U.S. Pat. No. 5,401,586, which in turn is acontinuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993, nowabandoned, which in turn is a continuation of Ser. No. 08/042,649 filedApr. 5, 1993, now abandoned.

[0012] This patent application is further a continuation-in-part ofco-pending Ser. No 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/980,985 filed Oct. 20, 1997, nowabandoned, which in turn is a continuation of Ser. No. 08/636,179 filedApr. 22, 1996, now abandoned, which in turn is a continuation-in-part ofSer. No. 08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424,which in turn is a divisional of Ser. No. 08/402,925 filed Mar. 13,1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/380,372 filed Jan. 30, 1995, nowU.S. Pat. No. 5,480,731, which is in turn a continuation of Ser. No.08/153,026 filed Nov. 17, 1993, now U.S. Pat. No. 5,395,703, which inturn is a divisional of Ser. No. 07/858,662 filed Mar. 27, 1992, nowU.S. Pat. No. 5,314,758.

[0013] This patent application is still further a continuation-in-partof co-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 09/071,316 filed May 1, 1998, nowU.S. Pat. No. 6,080,497, which in turn is a continuation-in-part of Ser.No. 08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/165,085 filed Dec. 10, 1993, now U.S. Pat. No. 5,401,586, whichin turn is a continuation-in-part of Ser. No. 08/000,101 filed Jan. 4,1993, now abandoned, which in turn is a continuation-in-part of Ser. No.07/967,407 filed Oct. 26, 1992, now abandoned, which in turn is acontinuation-in-part of Ser. No. 07/913,209 filed Jul. 15, 1992, nowabandoned, which in turn is a continuation-in-part of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

[0014] This patent application is yet further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 09/100,578 filed Jun. 19, 1998, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/380,372 filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, whichis in turn a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993,now U.S. Pat. No. 5,395,703, which in turn is a divisional of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

[0015] This patent application is also a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 09/131,219 filed Aug. 7, 1998, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/380,372 filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, whichis in turn a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993,now U.S. Pat. No. 5,395,703, which in turn is a divisional of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

[0016] This patent application is further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 09/161,573 filed Sep. 28, 1998, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/380,372 filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, whichis in turn a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993,now U.S. Pat. No. 5,395,703, which in turn is a divisional of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

[0017] This patent application is still further a continuation-in-partof co-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 09/161,580 filed Sep. 28, 1998, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/380,372 filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, whichis in turn a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993,now U.S. Pat. No. 5,395,703, which in turn is a divisional of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

[0018] This patent application is yet further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 09/420,165 filed Oct. 18, 1999, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/380,372 filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, whichis in turn a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993,now U.S. Pat. No. 5,395,703, which in turn is a divisional of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

[0019] The present invention relates to the art of a corrosion-resistantmetal material and more particularly to a coated copper metal which iscoated with a corrosion resistant tin and zinc alloy.

INCORPORATION BY REFERENCE

[0020] As background material so that the specification need not specifyin detail what is known in the art, U.S. Pat. Nos. 4,934,120; 4,982,543;4,987,716; 4,934,120; 5,001,881; 5,022,203; 5,259,166; and 5,301,474 areincorporated herein by reference to illustrate metal roofing systems ofthe type to which this invention can be used. U.S. Pat. No. 5,455,122 isincorporated herein by reference to illustrate petroleum receptacles ofthe type to which this invention can be used. U.S. Pat. Nos. 5,296,300;5,314,758; 5,354,624; 5,395,702; 5,395,703; 5,397,652; 5,401,586;5,429,882; 5,455,122; 5,470,667; 5,480,731; 5,489,490; 5,491,035;5,491,036; 5,492,772; 5,520,964; 5,597,656; 5,616,424; 5,667,849,5,695,822; and 6,080,497 and U.S. patent application Ser. No.07/913,209, filed Jul. 15, 1992; Ser. No. 08/042,649, filed Apr. 5,1993; Ser. No. 08/929,623, filed Sep. 15, 1997; Ser. No. 08/980,985,filed Oct. 20, 1997; Ser. No. 09/100,578, filed Jun. 19, 1998; Ser. No.09/131,219, filed Aug. 7, 1998; Ser. No. 09/161,573, filed Sep. 28,1998; Ser. No. 09/161,580, filed Sep. 28, 1998; Ser. No. 09/420,165,filed Oct. 18, 1999; and Ser. No. 09/634,828 filed Aug. 9, 2000 areincorporated herein by reference to illustrate various coatings andprocesses that can be used to coat, treat and use the coated base metal.

BACKGROUND OF THE INVENTION

[0021] The present invention relates to the art of a base metal which iscoated with a corrosion resistant metal alloy, which corrosion-resistantmetal material can be used in a wide variety of applications such as,but not limited to, architectural or building materials such as roofingmaterials, siding materials, window frames, sheet metal, metal platesand the like; truck and automotive products such as, but not limited to,gasoline tanks, filter casings, body molding, body parts and the like;household products such as, but not limited to, appliance housings,electrical housings, light fixtures and the like; marine products suchas, but not limited to, boat hulls, boat masts, dock system components,water retaining systems; and/or other types of metal materials such as,but not limited to, tools, machinery, wires, cables, electrodes, solderand the like. The invention also relates to several novel methods andprocesses for forming base metals coated with the metal alloy materials,such as but not limited to, coated metal forming by a hot-dip process(i.e plating of metal alloy and subsequent flow heating, immersion inmolten metal alloy, metal spraying of metal alloy, and/or roller coatingof metal alloy), pretreatment of the base metal prior to metal alloycoating, applying an intermediate barrier metal layer prior to metalalloy coating, post-treating the metal alloy or coated base metal,and/or forming the metal alloy or coated base metal into a variety ofdifferent articles.

[0022] Over the last several years, there has been a trend in theindustry to produce products which are higher in quality, areenvironmentally friendly, and are safe for use by humans, animals,and/or plants. This push for quality, safety and environmentalfriendliness is very apparent in the automotive industry wherein bothconsumer groups and environmental organizations are constantly lobbyingfor safer, higher-quality vehicles that are more fuel efficient and lessdetrimental to the environment. Recycling old vehicles has been oneanswer to resolving the environmental issues associated with vehicleswhich have run out their useful life. Automotive salvage markets havedeveloped for these vehicles. The vehicles are partially dismantled andsold as scrap metal wherein the metal is melted down and reformed intovarious parts. Because of the environmentally-un-friendly nature oflead, the gasoline tanks of vehicles must be removed prior to therecycling of the vehicle. Gasoline tanks are commonly made of carbon orstainless steel that are coated with a terne alloy.

[0023] Other industries have also demanded higher quality products.These industries include the building industry and marine industry.Corrosion-resistant products that are exposed to various corrosiveenvironments are constantly in demand. Historically, terne coatedproducts were used to coat carbon steel sheets and other carbon steelarticles to effectively and inexpensively provide corrosion-resistanceto the carbon steel in various applications. Terne or terne alloy is aterm commonly used to describe a metal alloy containing about 80% leadand the balance tin. The terne alloy is commonly applied to a the carbonsteel by immersing the carbon steel in a molten bath of terne metal by acontinuous or batch process.

[0024] Although terne coated metals have excellent corrosion-resistantproperties and have been used in various applications, terne coatedmaterials have been questioned due to environmental concerns based onthe high lead content of the alloy. Environmental and public safety lawshave been proposed and/or passed prohibiting or penalizing the user ofmaterials containing a significant portion of lead. As a result, theseterne coated articles are typically disposed of in dumping yards orlandfills. Not only do these the terne coated articles take up space inthe landfills, but there is a concern with the lead leaching from theterne coating into the landfill site and potentially contaminating thesurrounding area and underground water reservoirs.

[0025] The lead content in terne coated materials is also of someconcern for building materials and marine applications. This isespecially a concern when the terne coated materials are in contact withdrinking water. In many countries, lead pipe has been outlawed to reducethe amount of lead in the water. In many remote locations throughout theworld, piped water or well water is not readily available. As a result,structures, such as roof systems, are built to capture rain and to storethe rain water for later use. These roof systems supply an importantwater source for inhabitants utilizing such structures. Roof systemsthat are designed to collect rain water are typically made of metal toincrease the longevity of the roofing system. Typically, the roofsystems are made of carbon steel since such metal is less expensive.Terne alloy has historically been used due to its relatively low cost,ease of application, excellent corrosion-resistant properties anddesirable colorization during weathering. Roof systems have been made ofother metals, but to much less extent due to higher cost and naturalcorrosion resistance. Such metals include stainless steel, copper,copper alloys and aluminum.

[0026] Terne coated materials have typically been coated with a 6-8 lb.coating (7-11 microns), which is a very thin coating. This thin coatingcommonly includes pinholes. Terne coated materials that are drawn orformed in various types of materials such as, but not limited to,gasoline tanks, corrugated roofing materials and the like typicallyincluded one or more defects in the coating. Due to the thin layer ofthe terne coating and the pinholes in the coating, the coating on thebase metal, upon being drawn by a die or by being formed tended to tearor shear the terne coating and/or elongate the pin holes on the coatingthereby exposing the base metal. These exposed surfaces typicallycorroded at a faster rate than the unexposed surfaces. The corrodedregions about the coated areas, in some instances, compromised theadherence of the coated area, thereby resulting, in some instances, toflaking of the coated regions. These corroded regions compromised, insome instances, rapidly compromised the structural integrity, safetyand/or performance of the coated base metal. Another disadvantage ofusing a terne alloy coating is the softness of the terne layer. Thesoftness of the terne coating is susceptible to damage from the abrasivenature of forming machines and to environments that subject the ternecoating to frequent contact with other materials.

[0027] Terne alloys have a further disadvantage in that the newlyapplied terne is very shiny and highly reflective. As a result, in somebuilding applications, the highly reflective coating cannot immediatelybe used. The terne coating eventually loses its highly reflectiveproperties as the components of the terne coating are reduced(weathered); however, the desired amount of reduction commonly takesabout 1.5 to 2 years when the terne coating is exposed to theatmosphere. The storage of the terne coated base metal significantlyprolongs the weathering of the terne coated materials.

[0028] Metallic coatings such as tin or zinc have been tested assubstitutes for terne coatings with limited success. The most popularprocess for applying a tin coating to a base metal is by anelectroplating process. In an electroplating process, the coatingthickness is very thin and typically ranges between 0.3 microns to 30microns. The very thin thicknesses of the tin coating typically resultsin a tin coating having a network of small pinholes, thereby making thecoated material generally unacceptable for use in corrosiveenvironments, such as on building materials, marine materials, andautomotive products. Such tin plated base metals can include a flash orintermediate metal layer (plated layer) to reduce the pinhole problemsinherent with the tin plating process; however, the corrosioneffectiveness of the plated tin layer, in some applications, is lessthan terne 0.25 coated materials. The tin plated layer is alsosusceptible to flaking or being scrapped off when the tin plated basemetal is drawn through a die and/or formed into various components. Theflaking of the tin coating can also cause premature clogging of filtersystems and liquid lines, such as in gasoline lines and filters when tinplated based metals are formed into gasoline tanks. The pinholesproblem, flaking and/or scraping problem that is associated with platedtin coatings is very problematic since tin is not electroprotectiveunder oxidizing conditions. Consequently, discontinuities in the platedtin coating can result in the corrosion of the exposed base metal.

[0029] Coating a base metal with zinc metal, commonly known asgalvanizing, is another popular metal treatment to inhibit corrosion.Zinc is a desirable metal to coat materials because of its relativelylow cost, ease of application, and excellent corrosion resistance. Zincis also electroprotective under oxidizing conditions and inhibits orprevents the exposed metal, due to discontinuities in the zinc coating,from rapidly corroding. This electrolytic protection extends away fromthe zinc coating over exposed metal surfaces for a sufficient distanceto protect the exposed metal at cut edges, scratches, and other coatingdiscontinuities. Although zinc coatings bond to many types of metals,the bond is typically not very strong thereby resulting in the zinccoating flaking off the base metal over time and/or when being formed.The flaking of zinc, like the flaking of tin coatings, can causepremature clogging of filter systems and liquid lines when zinc coatedbase metal is formed into gasoline tanks or used in other liquidsystems. The flaking of the zinc coating can also result in an undesiredand/or disfigured product over a short period of time. Zinc also doesnot form a uniform and/or thick coating when coating on various types ofbase metals. Zinc is also a very rigid and brittle metal, thus tends tocrack and/or flake off when the zinc coating is formed and/or drawnthrough a die. When zinc oxidizes, the zinc coating forms a whitepowdery texture (zinc oxide). This white powdery substance isundesirable for many building applications and in various otherenvironments and applications. One such coating process is disclosed inU.S. Pat. No. 5,399,376, which is incorporated herein by reference.Consequently, the use of a tin coating or a zinc coating as a substitutefor terne coatings has not been highly reliable, commercially acceptableor a cost effective substitute for traditional terne coatings.

[0030] Metal coatings that include electroplated tin and zinc have alsobeen used to coated base metals. Electroplating a tin and zinc mixtureonto a steel sheet is disclosed in Japanese Patent Application No.56-144738 filed Sep. 16, 1981, which is incorporated herein byreference. The Japanese patent application discloses the plating of asteel sheet with a tin and zinc mixture to form a coating thickness ofless than 20 microns. The Japanese patent application discloses thatafter plating, pinholes exist in the coating and subject the coating tocorrosion. The pin holes are a result of the crystalline layer of thetin and zinc mixture slowly forming during the plating process.Consequently, the Japanese patent application discloses that the platedtin and zinc coating must be covered with chromate or phosphoric acid tofill the pin holes to prevent corrosion. The Japanese patent applicationdiscloses that a preplated layer of nickel, tin or cobalt on the steelsheet surface is needed so that the plated tin and zinc mixture willadhere to the steel sheet.

[0031] The coating of steel articles by a batch hot-dip process with atin, zinc and aluminum mixture is disclosed in U.S. Pat. No. 3,962,501issued Jun. 8, 1976, which is incorporated herein by reference. The '501patent discloses that the tin, zinc and aluminum mixture resistsoxidation and maintains a metallic luster. The '501 patent disclosesthat the molten tin and zinc alloy is very susceptible to oxidationresulting in viscous oxides forming on the surface of the molten tin andzinc alloy. These viscous oxides cause severe problems with the coatingprocess. While the steel article is immersed in the molten alloy, alarge amount of dross forms on the surface of the molten alloy. Thedross results in non-uniformity of the coating and the formation of pinholes as the steel article is removed from the molten metal. The '501patent discloses that the addition of up to 25% aluminum to the tin andzinc alloy inhibits dross formation, reduces Zn—Fe alloy formation, andreduces viscous oxide formation on the molten bath surface.

[0032] The treatment of a steel sheet by plating tin and zinc followedby heat flowing is disclosed in U.S. Pat. No. 4,999,258, which isincorporated herein by reference. The '258 patent discloses a steelsheet plated with a layer of tin and a subsequent layer of zinc. The tinand zinc plated layers are then heated until the zinc alloys with thetin. The tin is applied at 0.2-1.0 g/m² and the zinc is applied at0.01-0.3 g/m². The '258 patent also discloses that when less than 1%zinc is used, the beneficial effect of the zinc is null; however, whenmore than 30% zinc is used, the coating will rapidly corrode underadverse environments. The '258 patent also discloses that a nickelplated layer is preferably applied to the steel sheet prior to applyingthe tin and zinc plated layers to improve corrosion resistance. The heattreated tin and zinc layer can be further treated by applying a chromatetreatment to the plated layer further improve corrosion resistance.

[0033] Due to the various environmental concerns and problems associatedwith corrosion-resistant coatings applied to base metals and theproblems associated with the inadvertent removal of thecorrosion-resistant coating during the forming and/or drawing of thecoated materials, there has been a demand for a coating or metalmaterial that is corrosion-resistant, is environmentally friendly, andresists damage during forming into end components. Many of these demandswhere met by the tin alloy or the tin and zinc alloy and process andmethod for applying these alloys to a base metal which is disclosed inAssignee's U.S. Pat. Nos. 5,314,758; 5,354,624; 5,395,702; 5,395,703;5,397,652; 5,401,586; 5,429,882; 5,455,122; 5,470,667; 5,480,731;5,489,490; 5,491,035; 5,491,036; 5,492,772; 5,520,964; 5,597,656;5,616,424; 5,667,849; 5,695,822; and 6,080,497; and Assignee's U.S.patent application No. Ser. No. 09/634,828 filed Aug. 9, 2000, all ofwhich are incorporated herein by reference.

[0034] The use of copper base metals for architectural materials andother applications present unique challenges. Copper is typically morecorrosion resistant than carbon steel in many environments. Commercialcopper is used for the roofing material and for other types ofarchitectural materials due to its desirable mechanical properties andnatural corrosive resistant properties. Copper is one of the strongestpure metals. It is moderately hard, extremely tough, and wear resistant.Though copper in its commercially pure state is very formable thusrelatively easily shaped, the copper can be further softened by anannealing process to further improve its formability. Copper alloys canalso be used in the architectural materials. Some common alloys ofcopper are copper-zinc alloys or copper-nickel alloys. Generally, thecopper alloys reduce the formability of the architectural materials.Although copper or copper alloy materials have properties that areadvantageous in various applications, when copper oxidizes, the oxideforms a black, green or blue-green layer. This color change isunacceptable in a variety of applications. Uncoated copper can also beused to collect water; however, the oxidized copper tends to mix withthe water and adversely affects the taste and color of the water. Asdisclosed in U.S. Pat. No. 5,354,624, copper base materials can becoated with a tin alloy to form a corrosion resistant material that ispliable and that resists formation of a black, green or blue-green layerduring oxidation. The life of the copper is significantly extended bycoating the copper with the tin alloy.

[0035] Due to the various environmental concerns and problems associatedwith corrosion-resistant coatings applied to copper materials and theproblems associated with the forming of the coated copper material intovarious types of components, there has been a demand for a coppermaterial that is corrosion-resistant, is cost effective to use, isenvironmentally friendly, resists damage during forming, is pliable,does not oxidize to produce an undesirable color, and is not highlyreflective.

SUMMARY OF THE INVENTION

[0036] The present invention relates to a product and method ofproducing a corrosion-resistant, environmentally friendly metalmaterial. More particularly, the invention relates the coating of a basemetal with a corrosion resistant metal alloy which forms acorrosive-resistant barrier on the base metal. Even more particularly,the invention relates to a copper containing base metal coated with acorrosion-resistant metal alloy which coated base metal is formed intotruck and automotive products, architectural or building materials,household materials, marine products; and/or formed into tools ormachinery.

[0037] In accordance with the principal feature of the invention, thereis provided a corrosion resistant metal alloy primarily including tinand zinc. In one embodiment of the invention, the corrosion resistantmetal alloy is coated on a copper containing base metal, which coatedbase metal is formed, molded, and/or drawn into a metal article. Thecopper containing base metal includes pure copper base metals; copperalloy base metals (e.g. brasses, bronzes, copper-nickels, etc.); metals(e.g. stainless steel, carbon steel, nickel alloys, titanium or titaniumalloys, aluminum or aluminum alloys, tin, etc.) that are plated, clad,or otherwise coated and/or bonded with copper and/or copper alloy.

[0038] In accordance with one aspect of the invention, the corrosionresistant metal alloy is a tin and zinc alloy. In one embodiment of theinvention, the tin and zinc constituents of the tin and zinc alloymaintain their own integrity (structure or composition) in the compositewith one phase metal being a matrix surrounding distinct globules orphases of the second phase metal. The tin and zinc system is a dualstrata of metal globules or phases, each globule or phase being distinctfrom the other in structure or composition. The lowest weight percentageof zinc in an eutectic tin and zinc mixture is a tin rich mixturecontaining about 90-91 weight percent tin and about 9-10 weight percentzinc. For the tin rich matrix or phase and zinc rich globules or phasesto form in a tin and zinc alloy, the zinc must make up at least overabout 9-10 weight percent of the tin and zinc alloy. A zinc content overabout 9-10 weight percent of the tin and zinc alloy results in the zincprecipitating out of the tin and forming zinc globules or phases withinthe tin and zinc alloy. The tin content of the tin and zinc alloy mustbe at least about 15 weight percent of the tin and zinc alloy so thatthere is a sufficient amount of tin within the tin and zinc alloy toform the tin phase about the zinc phase. A metal alloy that primarilyincludes tin and zinc but has a zinc content that is equal to or lessthan the minimum eutectic weight percentage of zinc is defined herein asa tin alloy, instead of a tin and zinc alloy. A tin and zinc alloy isdefined herein as a metal alloy that includes at least about 15 weightpercent tin and at least about 10 weight percent zinc and the tincontent plus zinc content of the metal alloy constitutes at least amajority of the metal alloy. One of the important and desirableproperties of the tin and zinc alloy is its excellentcorrosion-resistance in many different environments. The tin and zincalloy is very corrosion resistant in marine environments whereinchloride salts are common, and in industrial environments wherein sulfurand sulfur compounds are present. The excellent corrosion-resistance ofthe tin and zinc alloy is believed to result from the formation of astable, continuous, adherent, protective film on the surface. Thedamaged film generally reheals itself quickly. Because of the generalinertness of the film, that is at least partially formed of tin and zincoxide, in most atmospheres, the corrosion resistant tin and zinc alloyis considered to be environmentally safe and friendly, and considered asafe material to be used in the human environment. The tin and zincalloy also forms over time a dull, low-reflecting surface; has apleasing color; performs well in low temperatures; has a relatively lowcoefficient of thermal expansion; resists degradation by solar energy;can be molded, cast, formed, drawn, soldered, painted and/or colored;and/or can be installed in a variety of weather conditions. The tin andzinc alloy is further a cost effective material for use in structuresused in corrosive environments such as in the tropics and other areaswhere buildings are exposed to strong winds, corrosive fumes, and/ormarine conditions. In another and/or alternative embodiment of theinvention, the tin content plus the zinc content in the tin and zincalloy makes up over 50 weight percent of the tin and zinc alloy. In oneaspect of this embodiment, the tin content plus the zinc content in thetin and zinc alloy is at least about 60 weight percent of the tin andzinc alloy. In another and/or alternative aspect of this embodiment, thetin content plus the zinc content in the tin and zinc alloy is at leastabout 75 weight percent of the tin and zinc alloy. In yet another and/oralternative aspect of this embodiment, the tin content plus the zinccontent in the tin and zinc alloy is at least about 80 weight percent ofthe tin and zinc alloy. In still yet another and/or alternative aspectof this embodiment, the tin content plus the zinc content in the tin andzinc alloy is at least about 85 weight percent of the tin and zincalloy. In a further and/or alternative aspect of this embodiment, thetin content plus the zinc content in the tin and zinc alloy is at leastabout 90 weight percent of the tin and zinc alloy. In yet a furtherand/or alternative aspect of this embodiment, the tin content plus thezinc content in the tin and zinc alloy is at least about 95 weightpercent of the tin and zinc alloy. In still a further and/or alternativeaspect of this embodiment, the tin content plus the zinc content in thetin and zinc alloy is at least about 98 weight percent of the tin andzinc alloy. In still yet a further and/or alternative aspect of theembodiment, the tin plus zinc content in the tin and zinc alloy is atleast about 99 weight percent of the tin and zinc alloy.

[0039] In accordance with another and/or alternative aspect of theinvention, a metal alloy is a tin alloy, as defined above, thatprimarily includes tin, and zinc content is equal to or less than theminimum eutectic weight percentage of zinc in the tin alloy. As such,the tin alloy is a metal alloy that includes at least a majority of tinand less than 10 weight percent zinc. The corrosion resistant tin alloyforms a corrosion resistant coating that protects the surface of thebase metal from oxidation. The corrosion resistant tin alloy providesprotection to the base metal in a variety of environments such as rural,industrial, and marine environments. The corrosion resistant tin alloyalso performs well in low temperatures; has a relatively low coefficientof thermal expansion; has a pleasing color; resists degradation by solarenergy; can be molded, cast, formed, drawn, soldered, painted and/orcolored; and/or can be installed in a variety of weather conditions.Because of the relative inertness of the tin oxide in many environments,the corrosion resistant tin alloy is considered to be environmentallysafe and friendly and considered a safe material to be used in the humanenvironment. The corrosion resistant tin alloy is also a cost effectivematerial for use in structures erected in corrosive environments, suchas in the tropics and other areas where buildings are exposed to strongwinds, corrosive fumes, and/or marine conditions. In one embodiment ofthe invention, the tin content in the tin alloy makes up over 50 weightpercent of the tin alloy. In one aspect of this embodiment, the tincontent in the tin alloy is at least about 75 weight percent of the tinalloy. In another and/or alternative aspect of this embodiment, the tincontent in the tin alloy is at least about 80 weight percent of the tinalloy. In yet another and/or alternative aspect of this embodiment, thetin content in the tin alloy is at least about 85 weight percent of thetin alloy. In still yet another and/or alternative aspect of thisembodiment, the tin content in the tin alloy is at least about 90 weightpercent of the tin alloy. In a further and/or alternative aspect of thisembodiment, the tin content in the tin alloy is at least about 95 weightpercent of the tin alloy. In yet a further and/or alternative aspect ofthis embodiment, the tin content in the tin alloy is at least about 98weight percent of the tin alloy. In still a further and/or alternativeaspect of this embodiment, the tin content in the tin alloy is at leastabout 99 weight percent of the tin alloy.

[0040] In accordance with yet another aspect of the invention, thecorrosion resistant tin alloy and corrosion resistant tin and zinc alloycontain a low lead content. The lead source in the tin alloy or the tinand zinc alloy can be from impurities in the raw tin and/or zinc oreused to make the metal alloy, and/or can be from directed additions oflead to the metal alloy. In some metal alloy combinations, lead in themetal alloy positively affects one or more physical and/or chemicalproperties of the metal alloy. Metal alloys that include little or nolead are considered more environmentally friendly, and the prejudicesassociated with the lead containing alloys are overcome. When the metalalloy includes lead, the lead content is generally at least about 0.0001weight percent of the metal alloy. In one embodiment of the invention,the tin alloy and the tin and zinc alloy include no more than about 10weight percent lead. In one aspect of this embodiment, the metal alloyinclude less than about 2 weight percent lead. In another and/oralternative aspect of this embodiment, the metal alloy include less thanabout 1 weight percent lead. In yet another and/or alternative aspect ofthis embodiment, the tin alloy and the tin and zinc alloy include lessthan about 0.5 weight percent lead. In still another and/or alternativeaspect of this embodiment, the metal alloy include less than about 0.05weight percent lead. In still yet another and/or alternative aspect ofthis embodiment, the metal alloy include less than about 0.01 weightpercent lead. In a further and/or alternative aspect of this embodiment,the metal alloy include less than about 0.005 weight percent lead. Instill a further and/or alternative aspect of this embodiment, the metalalloy include less than about 0.001 weight percent lead.

[0041] In accordance with a further and/or alternative aspect of theinvention, the tin alloy and tin and zinc alloy include one or moreadditives. In one embodiment of the invention, the one or more additivesgenerally constitute less than about 25 weight percent of the metalalloy. In one aspect of this embodiment, the one or more additivesconstitute less than about 10 weight percent of the metal alloy. Inanother and/or alternative aspect of this embodiment, the one or moreadditives constitute less than about 5 weight percent of the metalalloy. In yet another and/or alternative aspect of this embodiment, theone or more additives constitute less than about 2 weight percent of themetal alloy. In still another and/or alternative aspect of thisembodiment, the one or more additives constitute less than about 1weight percent of the metal alloy. In still yet another and/oralternative aspect of this embodiment, the one or more additivesconstitute less than about 0.5 weight percent of the metal alloy. Inanother and/or alternative embodiment of the invention, the additivesinclude, but are not limited to, aluminum, antimony, arsenic, bismuth,boron, bromine, cadmium, carbon, chlorine, chromium, copper, cyanide,fluoride, iron, lead, magnesium, manganese, molybdenum, nickel,nitrogen, phosphorous, potassium, silicon, silver, sulfur, tellurium,titanium, vanadium, and/or zinc. The one or more additives included inthe corrosion resistant metal alloy are used, but are not limited, toenhance the mechanical properties of the alloy, to improve corrosionresistance of the metal alloy, to improve grain refinement of the metalalloy, to alter the color of the metal alloy, to alter thereflectiveness of the metal alloy, to inhibit oxidation of the metalalloy during forming or coating of the metal alloy and/or when the metalalloy is exposed in various types of environments, to inhibit drossformation during the forming or coating of the metal alloy, to stabilizeone or more components of the metal alloy, to improve the bonding of themetal alloy on the base metal and/or intermediate barrier metal layer onthe base metal, to improve the flowability of the metal alloy during theforming or coating process, to produce the thickness of heat createdintermetallic layer, and/or to reduce or inhibit the crystallization ofthe tin in the metal alloy. The inclusion of one or more additives inthe corrosion resistant metal alloy typically preform one or more of theabove listed functions and/or features in the metal alloy. As can beappreciated, the source or a portion of the source of one or more of theabove-listed additives in the tin alloy or tin and zinc alloy can befrom impurities in the raw tin and/or zinc ore used to make the metalalloy. The believed functions and features of select additives aredescribed below; however, the described additives may have additionalfunctions and features. Aluminum can reduce the rate of oxidation of themolten metal alloy; reduce dross formation during the coating process;alter the reflective properties of the metal alloy; alter the mechanicalproperties of the metal alloy (i.e. coatability, durability,flexibility, flowability, formability, hardness, and strength); and/orreduce the thickness of the heat created intermetallic layer to improvethe formability of the coated base metal. Antimony, bismuth, cadmium,and/or copper can prevent or inhibit the crystallization of the tin inthe metal alloy, which crystallization can weaken the bonding and/orresult in flaking of the corrosion resistant metal alloy; improve thebonding properties of the metal alloy to the base metal and/orintermediate barrier metal layer; alter the mechanical properties of themetal alloy; and/or alter the corrosion resistant properties of themetal alloy. Only small amounts of antimony, bismuth, cadmium, and/orcopper are needed to prevent and/or inhibit the crystallization of thetin in the metal alloy. This small amount can be as low as about0.001-0.05 weight percent, and typically as low as 0.001-0.004 weightpercent. Arsenic can alter the mechanical properties of the metal alloy.Cadmium, in addition to its bonding, corrosion resistant, stabilizingand/or mechanical altering properties, can reduce the rate of oxidationof the molten metal alloy; reduce dross formation during the coating orforming process of the metal alloy; alter the color and/or reflectiveproperties of the metal alloy; and/or improve the grain refinement ofthe metal alloy. Chromium can provide additional corrosion protection tothe metal alloy; alter the mechanical properties of the metal alloy;and/or alter the color and/or reflective properties of the metal alloy.Copper, in addition to its corrosion resistant, stabilizing and/ormechanical altering properties, can alter the color and/or reflectiveproperties of the metal alloy. Iron can alter the mechanical propertiesof the metal alloy; and/or alter the color of the metal alloy. Lead canprovide additional corrosion protection to the metal alloy; alter themechanical properties of the metal alloy; alter the color of the metalalloy; and/or improve the bonding properties of the metal alloy to thebase metal and/or intermediate barrier metal layer. Magnesium can alterthe mechanical properties of the metal alloy; reduce the anodiccharacteristics of the metal alloy; reduce the rate of oxidation of themolten metal alloy; and/or reduce dross formation during the forming orcoating process of the metal alloy. Manganese can provide additionalcorrosion protection to the metal alloy; improve the grain refinement ofthe metal alloy; and/or improve the bonding properties of the metalalloy to the base metal and/or intermediate barrier metal layer. Nickelcan provide corrosion protection to the metal alloy, especially inalcohol and chlorine containing environments; alter the mechanicalproperties of the metal alloy; and/or alter the color and/or reflectiveproperties of the metal alloy. Silver can alter the mechanicalproperties of the metal alloy; and/or alter the color and/or reflectiveproperties of the metal alloy. Titanium can improve the grain refinementof the metal alloy; alter the mechanical properties of the metal alloy;provide additional corrosion protection to the metal alloy; reduce therate of oxidation of the molten metal alloy; reduce dross formationduring the forming or coating process of the metal alloy; alter thecolor and/or reflective properties of the metal alloy; and/or improvethe bonding properties of the metal alloy to the base metal and/orintermediate barrier metal layer. Zinc can alter the mechanicalproperties of the metal alloy; provide additional corrosion protectionto the metal alloy, alter the color and/or reflective properties of themetal alloy; improve the bonding properties of the metal alloy to thebase metal and/or intermediate barrier metal layer, and/or stabilize thetin to inhibit or prevent crystallization of the tin in the metal alloy.

[0042] In accordance with another and/or alternative aspect of theinvention, the thickness of the corrosion resistant metal alloy isselected to provide the desired amount of corrosion resistant protectionto the surface of the base metal. Generally thinner coating thicknessescan be obtained by a plating process and thicker coating thicknesses canbe obtained by immersion in molten metal alloy. The selected thicknessof the coating will typically depend on the end use of the coated basemetal and/or the environment the coated base metal is to be used. A 6lb. coating on a base metal is a common thickness for a thin coating. A6 lb. coating has a coating thickness of about 7 microns. A 6 lb.coating is commonly applied by a plating process. In many instances,very thin coatings include one or more pin holes in the coating. A 40lb. coating is also a common coating having a thickness of about 50microns. A 40 lb. coating typically has few, if any, pin holes, and dueto the thicker coating, thus the thicker coating resists tearing whenthe coated base metal is drawn or formed into various types ofcomponents. Thicker metal alloy coatings are commonly used forautomotive components (i.e. gasoline tank shell members), and roofingand siding materials. In one embodiment of the invention, the metalalloy coating is applied by a single plating process. In one aspect ofthis embodiment, the thickness of the metal alloy coating is at leastabout 1 micron. In another and/or alternative aspect of this embodiment,the thickness of the metal alloy coating is at least about 2 microns. Instill another and/or alternative aspect of this embodiment, thethickness of the metal alloy coating is about 2-30 microns. In anotherand/or alternative embodiment of the invention, the metal alloy coatingis applied by a) multiple plating processes, b) single or multiplehot-dip processes, and/or c) at least one plating process and at leastone hot dip process. In one aspect of this embodiment, the thickness ofthe metal alloy coating is at least about 1 micron. In another and/oralternative aspect of this embodiment, the thickness of the metal alloycoating is up to about 2550. In still another and/or alternative aspectof this embodiment, the thickness of the metal alloy coating is about2.5-1270 microns. In yet another and/or alternative aspect of thisembodiment, the thickness of the metal alloy coating is about 7-1270microns. In still yet another and/or alternative aspect of thisembodiment, the thickness of the metal alloy coating is about 7-1250microns. In a further and/or alternative aspect of this embodiment, thethickness of the metal alloy coating is about 15 to 1250 microns. In yeta further and/or alternative aspect of this embodiment, the thickness ofthe metal alloy coating is about 25-77 microns. In still a furtherand/or alternative aspect of this embodiment, the thickness of the metalalloy coating is about 25-51 microns.

[0043] In accordance with still another and/or alternative aspect of theinvention, the base metal is a metal strip. A “strip” is defined asmetal in the form of a thin metal sheet that is or can be rolled into aroll of metal, as opposed to plates of metal or other configurations ofthe metal. Metal strip which has a thickness of less than about 127microns (0.005 inch) can break as the strip is pretreated and/or coatedwith a metal alloy coating at high process speeds. A high process speedis defined as a metal strip moving through the pretreatment process,intermediate barrier metal coating process, and/or metal alloy coatingprocess at a speed of about 60-400 ft/min. However, the metal stripthickness should not be too great so as to prevent the strip from beingable to be directed, at a relatively high speed, through thepretreatment process, if any, and the coating process. Metal strip whichis too thick is more difficult to heat when a heat created intermetalliclayer is to formed between the base metal and metal alloy coating and/orintermediate barrier metal, especially when the metal strip is moving athigh speeds and/or coated over a short period of time. Metal stripshaving too great of thickness are also difficult to maneuver ateconomical high speeds through the pretreatment process, if any, and thecoating process. In one embodiment of the invention, the thickness ofthe metal strip is thin enough such that the metal strip can be unrolledfrom a roll of metal, coated by a metal alloy coating, and re-rolledinto a roll of coated metal stip. In one aspect of this embodiment, thethickness of the metal strip is not more than about 5080 microns. Inanother and/or alternative aspect of this embodiment, the thickness ofthe metal strip is less than about 2540 microns. In yet another and/oralternative aspect of this embodiment, the thickness of the metal stripis less than about 1270 microns. In still another and/or alternativeaspect of this embodiment, the thickness of the metal strip is less thanabout 762 microns. In a further and/or alternative aspect of thisembodiment, the thickness of the metal strip is about 127-762 microns.In yet a further and/or alternative aspect of this embodiment, thethickness of the metal strip is about 254-762 microns. In still afurther and/or alternative aspect of this embodiment, the thickness ofthe metal strip is about 381-762 microns. In yet a further and/oralternative aspect of this embodiment, the thickness of the metal stripis about 127-381 microns. In still yet a further and/or alternativeaspect of this embodiment, the thickness of the metal strip is about508-762 microns. In another and/or alternative embodiment of theinvention, the thickness of the metal strip is not more than about 1588microns when the metal strip is formed of stainless steel, carbon steel,nickel alloys, titanium or titanium alloys. These types of metal stripare difficult to maneuver at economical, high speeds through the coatingprocess when the metal strip thickness is greater than 1588 microns. Inone aspect of this embodiment, metal strip made primarily of stainlesssteel, carbon steel, nickel alloys, titanium or titanium alloy strip hasa thickness of about 127-762 microns. In another and/or alternativeaspect of this embodiment, metal strip made primarily of stainlesssteel, carbon steel, nickel alloys, titanium or titanium alloy strip hasa thickness of about 255-762 microns.

[0044] In accordance with still yet another and/or alternative aspect ofthe invention, the base metal is a metal plate. In one embodiment of theinvention, the metal plate is a rectangular or square metal plate havinga length of about 1 to 15 feet and a width of about 1-20 feet. Inanother and/or alternative embodiment of the invention, the thickness ofthe metal plate is not more than about 51000 microns (2 inches). In oneaspect of this embodiment, the thickness of the metal plate is not morethan about 25400 microns. In another and/or alternative aspect of thisembodiment, the thickness of the metal plate is not more than about12700 microns. In still another and/or alternative aspect of thisembodiment, the thickness of the metal plate is not more than about 1270microns. In yet another and/or alternative aspect of this embodiment,the thickness of the metal plate is about 127-5080 microns. In still yetanother and/or alternative aspect of this embodiment, the thickness ofthe metal plate is about 127-1270 microns. In a further and/oralternative aspect of this embodiment, the thickness of the metal plateis about 127-381 microns.

[0045] In accordance with another and/or alternative aspect of theinvention, the base metal is primarily carbon steel that has been hotdip coated, clad and/or plated with copper and/or a copper alloy. In oneembodiment of the invention, the carbon steel base metal is a metalstrip. In one aspect of this embodiment, the thickness of the carbonsteel strip is less than about 2540 microns. In another and/oralternative aspect of this embodiment, the thickness of the carbon steelstrip is less than about 1588 microns. In yet another and/or alternativeaspect of this embodiment, the thickness of the carbon steel strip isless than about 1270 microns. In still and/or alternative another aspectof this embodiment, the thickness of the carbon steel strip is up toabout 762 microns. In a further and/or alternative aspect of thisembodiment, the thickness of the carbon steel strip is about 127-762microns. In yet a further and/or alternative aspect of this embodiment,the thickness of the carbon steel strip is about 254-762 microns. Instill a further and/or alternative aspect of this embodiment, thethickness of the carbon steel strip is about 381-762 microns. In anotherand/or alternative embodiment of the invention, the carbon steel basemetal is a metal plate. In still another and/or alternative embodimentof the invention, the thickness of the copper and/or copper alloy on thecarbon steel base metal is less than about 2540 microns. In one aspectof this embodiment, the thickness of the copper and/or copper alloy isless than about 1270 microns. In yet another and/or alternative aspectof this embodiment, the thickness of the copper and/or copper alloy isless than about 762 microns. In still and/or alternative another aspectof this embodiment, the thickness of the copper and/or copper alloy isabout 1-500 microns. In a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about3-255 microns. In yet a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-100 microns. In still a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-50 microns. In still yet a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-25 microns. In another and/or alternative aspect of this embodiment,the thickness of the copper and/or copper alloy is less than thethickness of the carbon steel base metal. In yet another and/oralternative embodiment of the invention, the copper and/or copper alloyis applied to the carbon steel base metal by plating. In still yetanother and/or alternative embodiment of the invention, the copperand/or copper alloy is applied to the carbon steel base metal bycladding. In a further and/or alternative embodiment of the invention,the copper and/or copper alloy is applied to the carbon steel base metalby hot dip coating.

[0046] In accordance with still another and/or alternative aspect of theinvention, the base metal is primarily stainless steel that has been hotdip coated, clad and/or plated with copper and/or a copper alloy.“Stainless steel” is used in its technical sense and includes a largevariety of ferrous alloys containing chromium and iron. Carbon steelbase metal that is plated with chromium and subsequently coated with ametal alloy coating by a hot dip process transforms the carbon steelinto stainless steel at least at the surface of the base metal surface.The stainless steel can also contain other elements or compounds suchas, but not limited to, nickel, nickel alloys, carbon, molybdenum,silicon, manganese, titanium, boron, copper, aluminum and/or variousother metals or compounds. Elements such as nickel can be flashed(plated) onto the surface of the stainless steel or directlyincorporated into the stainless steel. In one embodiment of theinvention, the stainless steel base metal is 304 or 316 stainless steel.In another and/or alternative embodiment of the invention, the stainlesssteel base metal is a metal strip. In one aspect of this embodiment, thethickness of the stainless steel strip is less than about 2540 microns.In another and/or alternative aspect of this embodiment, the thicknessof the stainless steel strip is less than about 1588 microns. In yetanother and/or alternative aspect of this embodiment, the thickness ofthe stainless steel strip is less than about 1270 microns. In stillanother and/or alternative aspect of this embodiment, the thickness ofthe stainless steel strip is up to about 762 microns. In a furtherand/or alternative aspect of this embodiment, the thickness of thestainless steel strip is about 127-762 microns. In yet a further and/oralternative aspect of this embodiment, the thickness of the stainlesssteel strip is about 254-762 microns. In still a further and/oralternative aspect of this embodiment, the thickness of the stainlesssteel strip is about 381-762 microns. In still another and/oralternative embodiment of the invention, the stainless steel base metalis a metal plate. In yet another and/or alternative embodiment of theinvention, the thickness of the copper and/or copper alloy on thestainless steel base metal is less than about 2540 microns. In oneaspect of this embodiment, the thickness of the copper and/or copperalloy is less than about 1270 microns. In yet another and/or alternativeaspect of this embodiment, the thickness of the copper and/or copperalloy is less than about 762 microns. In still and/or alternativeanother aspect of this embodiment, the thickness of the copper and/orcopper alloy is about 1-500 microns. In a further and/or alternativeaspect of this embodiment, the thickness of the copper and/or copperalloy is about 3-255 microns. In yet a further and/or alternative aspectof this embodiment, the thickness of the copper and/or copper alloy isabout 5-100 microns. In still a further and/or alternative aspect ofthis embodiment, the thickness of the copper and/or copper alloy isabout 5-50 microns. In still yet a further and/or alternative aspect ofthis embodiment, the thickness of the copper and/or copper alloy isabout 5-25 microns. In another and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is less thanthe thickness of the stainless steel base metal. In still yet anotherand/or alternative embodiment of the invention, the copper and/or copperalloy is applied to the stainless steel base metal by plating. In afurther and/or alternative embodiment of the invention, the copperand/or copper alloy is applied to the stainless steel base metal bycladding. In still a further and/or alternative embodiment of theinvention, the copper and/or copper alloy is applied to the stainlesssteel base metal by hot dip coating.

[0047] In accordance with yet another and/or alternative aspect of theinvention, the base metal is copper. Copper metal is known for itsmalleability properties and natural corrosion resistant properties.Copper metal that is coated with a metal alloy can be formed in avariety of simple and complex shapes. In one embodiment of theinvention, the copper base metal is a metal strip. In one aspect of thisembodiment, the thickness of the copper strip is not more than about5080 microns. In another and/or alternative aspect of this embodiment,the thickness of the copper strip is less than about 2540 microns. Inyet another and/or alternative aspect of this embodiment, the thicknessof the copper strip is less than about 1270 microns. In still anotherand/or alternative aspect of this embodiment, the thickness of thecopper strip is up to about 762 microns. In a further and/or alternativeaspect of this embodiment, the thickness of the copper strip is about127-762 microns. In yet a further and/or alternative aspect of thisembodiment, the thickness of the copper strip is about 254-762 microns.In still a further and/or alternative aspect of this embodiment, thethickness of the copper strip is about 381-762 microns. In still anotherand/or alternative embodiment of the invention, the copper base metal isa metal plate.

[0048] In accordance with still yet another and/or alternative aspect ofthe invention, the base metal is a copper alloy. “Copper alloys” as usedherein include, but are not limited to, brasses, bronzes, andnickel-copper alloys. Brass is defined as a copper alloy that includes amajority of copper and zinc. Bronze is defined as an alloy that includestin and a majority of copper. Brass and bronze are copper alloys withknown corrosion resistant properties in various environments. Althoughbrass and bronze are relatively corrosion resistant in manyenvironments, brass and bronze are susceptible to a greater degree ofcorrosion in some environments than others. Brass and bronze are alsorelatively bright and reflective materials which can be undesirable foruse in several applications. As a result, it has been found that brassand bronze coated with a corrosion resistant metal alloy can overcomesthese deficiencies. In one embodiment of the invention, the coppercontent of the brass is about 50.1-99 weight percent and the zinccontent is about 1-49.9 weight percent. In one aspect of thisembodiment, the brass includes one or more additives such as, but notlimited to, aluminum, beryllium, carbon, chromium, cobalt, iron, lead,manganese, magnesium, nickel, niobium, phosphorous, silicon, silver,sulfur, and/or tin. These additives typically alter the mechanicaland/or corrosion resistant properties of the brass. In another and/oralternative embodiment of the invention, the bronze includes one or moreadditives such as, but not limited to, aluminum, iron, lead, manganese,nickel, nitrogen, phosphorous, silicon, and/or zinc. In still anotherand/or alternative embodiment of the invention, the copper alloy basemetal is a metal strip. In one aspect of this embodiment, the thicknessof the copper alloy strip is not more than about 5080 microns. Inanother and/or alternative aspect of this embodiment, the thickness ofthe copper alloy strip is less than about 2540 microns. In yet anotherand/or alternative aspect of this embodiment, the thickness of thecopper alloy strip is less than about 1270 microns. In still anotherand/or alternative aspect of this embodiment, the thickness of thecopper alloy strip is less than about 762 microns. In a further and/oralternative aspect of this embodiment, the thickness of the copper alloystrip is about 127-762 microns. In yet a further and/or alternativeaspect of this embodiment, the thickness of the copper alloy strip isabout 254-762 microns. In still a further and/or alternative aspect ofthis embodiment, the thickness of the copper alloy strip is about381-762 microns. In yet another and/or alternative embodiment of theinvention, the copper alloy base metal is a metal plate.

[0049] In accordance with a further and/or alternative aspect of theinvention, the base metal is primarily made of aluminum, aluminumalloys, nickel alloys, tin, titanium, or titanium alloys that have beenhot dip coated, clad and/or plated with copper and/or a copper alloy.“Aluminum alloys” as used herein include, but are not limited to, alloysincluding at least about 10 weight percent aluminum. “Nickel alloys” asused herein include, but are not limited to, alloys including at leastabout 5 weight percent nickel. In one embodiment of the invention, thebase metal is primarily an aluminum metal strip that has been coated,clad and/or plated with copper and/or a copper alloy. In another and/oralternative embodiment of the invention, the base metal is primarily analuminum alloy metal strip that has been coated, clad and/or plated withcopper and/or a copper alloy. In yet another and/or alternativeembodiment of the invention, the base metal is primarily a nickel alloystrip that has been coated, clad and/or plated with copper and/or acopper alloy. In still another and/or alternative embodiment of theinvention, the base metal is primarily a tin metal strip that has beencoated, clad and/or plated with copper and/or a copper alloy. In stillyet another and/or alternative embodiment of the invention, the basemetal is primarily a titanium metal strip that has been coated, cladand/or plated with copper and/or a copper alloy. In a further and/oralternative embodiment of the invention, the base metal is primarily atitanium alloy metal strip that has been coated, clad and/or plated withcopper and/or a copper alloy. In one aspect of these embodiments, thethickness of the aluminum, aluminum alloy, nickel alloy, tin, titanium,or titanium alloy strip is less than about 2540 microns. In anotherand/or alternative aspect of these embodiments, the thickness of thealuminum, aluminum alloy, nickel alloy, tin, titanium, or titanium alloystrip is less than about 1588 microns. In yet another and/or alternativeaspect of these embodiments, the thickness of the aluminum, aluminumalloy, nickel alloy, tin, titanium, or titanium alloy strip is less thanabout 1270 microns. In still another and/or alternative aspect of theseembodiments, the thickness of the aluminum, aluminum alloy, nickelalloy, tin, titanium, or titanium alloy strip is up to about 762microns. In a further and/or alternative aspect of these embodiments,the thickness of the aluminum, aluminum alloy, nickel alloy, tin,titanium, or titanium alloy strip is about 127-762 microns. In yet afurther and/or alternative aspect of these embodiments, the thickness ofthe aluminum, aluminum alloy, nickel alloy, tin, titanium, or titaniumalloy strip is about 240-762 microns. In still a further and/oralternative aspect of these embodiments, the thickness of the aluminum,aluminum alloy, nickel alloy, tin, titanium, or titanium alloy strip isabout 381-762 microns. In yet a further and/or alternative embodiment ofthe invention, the base metal is primarily an aluminum metal plate. Instill a further and/or alternative embodiment of the invention, the basemetal is primarily an aluminum alloy metal plate. In still yet a furtherand/or alternative embodiment of the invention, the base metal isprimarily a nickel alloy plate. In another and/or alternative embodimentof the invention, the base metal is primarily a tin metal plate. In yetanother and/or alternative embodiment of the invention, the base metalis primarily a titanium metal plate. In still another and/or alternativeembodiment of the invention, the base metal is primarily a titaniumalloy metal plate. In yet another and/or alternative embodiment of theinvention, the thickness of the copper and/or copper alloy on thealuminum, aluminum alloy, nickel alloy, tin, titanium, or titanium alloybase metal is less than about 2540 microns. In one aspect of thisembodiment, the thickness of the copper and/or copper alloy is less thanabout 1270 microns. In yet another and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is less thanabout 762 microns. In still and/or alternative another aspect of thisembodiment, the thickness of the copper and/or copper alloy is about1-500 microns. In a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about3-255 microns. In yet a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-100 microns. In still a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-50 microns. In still yet a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-25 microns. In another and/or alternative aspect of this embodiment,the thickness of the copper and/or copper alloy is less than thethickness of the aluminum, aluminum alloy, nickel alloy, tin, titanium,or titanium alloy base metal. In still yet another and/or alternativeembodiment of the invention, the copper and/or copper alloy is appliedto the aluminum, aluminum alloy, nickel alloy, tin, titanium, ortitanium alloy base metal by plating. In a further and/or alternativeembodiment of the invention, the copper and/or copper alloy is appliedto the aluminum, aluminum alloy, nickel alloy, tin, titanium, ortitanium alloy base metal by cladding. In still a further and/oralternative embodiment of the invention, the copper and/or copper alloyis applied to the aluminum, aluminum alloy, nickel alloy, tin, titanium,or titanium alloy base metal by hot dip coating.

[0050] In accordance with yet a further and/or alternative aspect of theinvention, the base metal is pretreated prior to applying the metalalloy to the base metal. The pretreatment of the base metal is designedto remove dirt, oil, adhesives, plastic, paper and other foreignsubstances from the surface of the base metal; to remove oxides andother compounds from the base metal surface; etch the base metalsurface; and/or improve the bonding of the metal alloy coating to thesurface of the base metal. The pretreatment process may include one ormore process steps depending on the surface condition of the base metal.In one embodiment of the invention, the various steps of thepretreatment process for the base metal include one or more of thepretreatment process operations disclosed in U.S. Pat. No. 5,395,702,which is incorporated herein. In another and/or alternative embodimentof the invention, the pretreatment process includes, but is not limitedto, an abrasion process; an absorbent process; solvent and/or cleaningsolution process; a low oxygen environment process; a rinse process; apickling process; a chemical activation process; and/or a flux treatingprocess. In one aspect of this embodiment, each of these pretreatmentprocess can be use singly or in combination with one another. The typeand/or number of pretreatment process used generally depends on the typeof base metal and/or condition of the base metal surface. Thepretreatment process can be applied to a portion of the base metalsurface or the complete surface of the base metal. In still anotherand/or alternative embodiment of the invention, the abrasion process,absorbent process and/or solvent or cleaning process are designed toremove foreign materials and/or oxides from the base metal surface. Inone aspect of this embodiment, the abrasion process includes, but is notlimited to, the use of brushes, scrappers and the like to mechanicallyremove oxides and/or foreign material from the surface of the basemetal. In another and/or alternative aspect of this embodiment, theabsorbent process includes, but is not limited to, the use of absorbingmaterials (i.e. towels, absorbent paper products, sponges, squeegees,etc.) to mechanically remove oxides and/or foreign material from thesurface of the base metal. In still another and/or alternative aspect ofthis embodiment, the solvent or cleaning process includes, but is notlimited to, the use of water, detergents, abrasives, chemical solvents,and/or chemical cleaners to remove oxides and/or foreign material fromthe surface of the base metal. The abrasion process, absorbent process,and/or solvent or cleaning process can be use individually or inconjunction with one another to remove foreign materials and/or oxidesfrom the base metal surface. In yet another and/or alternativeembodiment of the invention, the low oxygen environment process isdesigned to inhibit the formation and/or reformation of oxides on thesurface of the base metal. The low oxygen environment may take onseveral forms such as, but not limited to, a low oxygen-containing gasenvironment and/or a low oxygen-containing liquid environment. Examplesof gases used in the low oxygen-containing gas environments include, butare not limited to, nitrogen, hydrocarbons, hydrogen, noble gassesand/or other non-oxidizing gasses. The one or more gases partially ortotally shield oxygen and/or other oxidizing elements or compounds fromthe base metal. In one aspect of this embodiment, the lowoxygen-containing gas environment includes nitrogen. Examples of liquidsused in the low oxygen-containing liquid environment include, but arenot limited to, non-oxidizing liquids and/or liquids containing a lowdissolved oxygen content. The liquids partially or totally shield oxygenand/or other oxidizing elements or compounds from the base metal. Inanother and/or alternative aspect of this embodiment, the lowoxygen-containing liquid environment includes heated water that is atleast about 100-110° F. In still another and/or alternative aspect ofthis embodiment, the low oxygen-containing environment is applied to thebase metal by spraying the low oxygen-containing environment onto thesurface of the base metal, partially or totally immersing the base metalin the low oxygen-containing environment, and/or encasing the base metalin the low oxygen-containing environment. In still yet another and/oralternative aspect of this embodiment, agitators are used in the lowoxygen-containing liquid environment to facilitate in the removal ofoxides and/or inhibit oxide formation on the base metal. The agitatorscan include brushes which contact the base metal. In still yet anotherand/or alternative embodiment of the invention, the rinsed process isdesigned to remove foreign materials, oxides, pickling solution,deoxidizing agent, fluxes, solvents, and/or cleaning solutions from thesurface of the base metal. In one aspect of this embodiment, the rinseprocess includes the use of a rinse solution that includes a low ornon-oxidizing liquid. In one design of this aspect, the low ornon-oxidizing liquid includes water that is at least about 70° F. Inanother and/or alternative aspect of this embodiment, the rinse solutioncan be applied to the surface of the base metal by spraying the rinsesolution onto the base metal and/or partially or totally immersing thebase metal in the rinse solution. In yet another and/or alternativeaspect of this embodiment, the rinse solution is agitated to facilitatein the cleaning of the base metal surface. In still yet another and/oralternative aspect of this embodiment, the rinse solution isrecirculated, diluted and/or temperature is maintained during therinsing process. In a further and/or alternative embodiment of theinvention, the pickling process is designed to remove a very thinsurface layer from the base metal. The removal of the thin layer fromthe base metal results in the partial or total removal of oxides and/orother foreign matter from the base metal surface. The removal of thethin surface layer from the base metal causes slight etching of the basemetal surface which results in the formation of microscopic valleys onthe base metal surface. These microscopic valleys increase the surfacearea to which the metal alloy and/or intermediate barrier metal layercan bond thereby facilitating in the formation of a stronger bondbetween the base metal and the metal alloy and/or intermetallic barriermetal layer. The pickling process includes the use of a picklingsolution which can be an acidic or a basic solution. In one aspect ofthis embodiment, the pickling solution is an acidic solution. The acidcan be an organic acid, an inorganic acid, or combinations thereof. Inone particular design of this aspect, the inorganic acid used in thepickling solution includes, but are not limited to, hydrobromic acid,hydroiodic acid, choleic acid, perchloric acid, hydrofluoric acid,sulfuric acid, nitric acid, hydrochloric acid, phosphoric acid, and/orisobromic acid. In another and/or alternative particular design of thisaspect, the organic acid used in the pickling solution includes, but arenot limited to, formic acid, propionic acid, butyric acid, and/orisobutyric acid. In another and/or alternative aspect of thisembodiment, the pickling solution includes a single acid. Typically, acopper or copper alloy surface can be satisfactorily cleaned or pickledwith the use of a single acid. In one particular design of this aspect,the pickling solution only includes an inorganic acid. In still anotherand/or alternative aspect of this embodiment, the pickling solutionincludes two or more acids. In some situations, the surface of the basemetal is more difficult to clean or pickle. Pickling solutions thatinclude two or more acids typically can provide a more rapid oxideremoval rate. In one particular design of this aspect, the picklingsolution contains a combination of hydrochloric acid and nitric acid.One specific formulation of this dual acid pickling solution is thepickling solution including about 5-25% by volume hydrochloric acid andabout 1-15% by volume nitric acid. A more specific formulation of thisdual acid pickling solution is the pickling solution including about5-15% by volume hydrochloric acid and about 1-5% by volume nitric acid.A yet more specific formulation of this dual acid pickling solution isthe pickling solution including about 10% by volume hydrochloric acidand about 3% by volume nitric acid. In yet another and/or alternativeaspect of this embodiment, the temperature of the pickling solution ismaintained to obtain the desired activity of the pickling solution. Inone particular design of this aspect, the pickling solution ismaintained at a temperature of above about 26° C. In another and/oralternative particular design of this aspect, the pickling solution ismaintained at a temperature of about 48-60° C. In yet another and/oralternative particular design of this aspect, the pickling solution ismaintained at a temperature of about 53-56° C. Higher acidconcentrations and/or higher acid temperatures will typically increasethe activity and aggressiveness of the pickling solution. In yet anotherand/or alternative aspect of this embodiment, the pickling solution isagitated to prevent or inhibit the pickling solution from stagnating,varying in concentration, varying in temperature, and/or to remove gaspockets which form on the base metal surface. In one particular designof this aspect, the pickling solution is at least partially agitated byplacing agitators in a pickling tank and/or by recirculating thepickling solution in a pickling tank. Typically, agitation brushes inthe pickling tank contacts base metal as it passes through the picklingtank to facilitate in oxide removal and cleaning of the base metalsurface. In a further and/or alternative aspect of this embodiment, thebase metal is exposed to the pickling solution for a sufficient time toproperly clean and/or pickle the surface of the base metal. In oneparticular design of this aspect, the total time for pickling the basemetal is less than about 10 minutes. In another and/or alternativeparticular design of this aspect, the total time for pickling the basemetal is less than about two minutes. In still another and/oralternative particular design of this aspect, the total time forpickling the base metal is less than about one minute. In still yetanother and/or alternative particular design of this aspect, the totaltime for pickling the base metal is about 5-60 seconds. In a furtherand/or alternative particular design of this aspect, the total time forpickling the base metal is about 10-20 seconds. In still a furtherand/or alternative aspect of this embodiment, the pickling solution isapplied to the base metal by spray jets. In yet a further and/oralternative aspect of this embodiment, the base metal is partially orfully immersed in the pickling solution contained in a pickling tank. Instill a further and/or alternative embodiment of the invention, thechemical activation process is designed to remove oxides and/or foreignmaterial from the base metal surface. In one aspect of this embodiment,the chemical activation process includes subjecting the base metalsurface to a deoxidizing agent. Various types of deoxidizing agents maybe used. In another and/or alternative aspect of this embodiment, thedeoxidizing agent includes zinc chloride. In one particular design ofthis aspect, the deoxidizing agent includes at least about 1% by volumezinc chloride. In another and/or alternative particular design of thisaspect, the deoxidizing agent includes at least about 5% by volume zincchloride. The zinc chloride removes oxides and foreign materials fromthe base metal surface and/or provides a protective coating whichinhibits oxide formation on the base metal surface. In still anotherand/or alternative aspect of this embodiment, the temperature of thezinc chloride solution is at least about ambient temperature (about15-32° C.). In yet another and/or alternative aspect of this embodiment,the deoxidizing solution is agitated to maintain a uniform solutionconcentration and/or temperature. In one particular design of thisaspect, the agitators include brushes which contact the base metal. Instill yet another and/or alternative aspect of this embodiment, smallamounts of acid are included to the deoxidizing solution to enhanceoxide removal. In one particular design of this aspect, hydrochloricacid is included to the deoxidizing solution. In one specificformulation of this design, the deoxidizing solution includes about1-50% by volume zinc chloride and about 0.5-15% by volume hydrochloricacid. In another and/or alternative specific formulation of this design,the deoxidizing solution includes about 5-50% by volume zinc chlorideand about 1-15% by volume hydrochloric acid. In a further and/oralternative aspect of this embodiment, the base metal is subjected tothe deoxidizing solution for less than about 10 minutes. In oneparticular design of this aspect, the base metal is subjected to thedeoxidizing solution for up to about one minute. In still a furtherand/or alternative aspect of this embodiment, the deoxidizing solutionis applied to the base metal by spray jets. In yet a further and/oralternative aspect of this embodiment, the base metal is partially orfully immersed in the deoxidizing solution contained in a deoxidizingtank.

[0051] In accordance with still a further and/or alternative aspect ofthe invention, one or more surfaces of the base metal is coated with anintermediate barrier metal layer prior to applying the metal alloy tothe base metal. The intermediate barrier metal layer is designed toimprove the bonding of the metal alloy coating to the surface of thebase metal. The application of an intermediate barrier metal layer canbe used as a substitute for one or more pretreatment process, or can beapplied after one or more pretreatment process have been applied to thesurface of the base metal. The intermediate barrier metal process isdesigned to coat one or more surface areas of the base metal with a thinmetal coating. The intermediate metal barrier is applied to part of orthe complete surface of the base metal by a plating process, a platingand subsequent flow heating process, a metal spraying process, a coatingroller process, immersion process in molten metal prior to applying themetal alloy coating to the base metal, and/or pickling process. Theintermediate barrier metal typically provides additional corrosionresistance to the base metal in many types of corrosive environments. Inmarine environments where the coated base metal is exposed to saltand/or halogens (i.e. chlorine, fluorine, etc.), the use of anintermediate barrier metal can significantly extend the life of thecoated base metal. The use of an intermediate barrier metal can alsoenhance the bonding of the metal alloy coating to the base metal. Somebase metals may form a weaker bond with certain formulations of themetal alloy. The application of an intermediate barrier metal on part ofor the complete surface of the base metal can, in many instances,improve the strength of the bond of the metal alloy coating to the basemetal. The intermediate barrier metal includes copper and/or nickel.Other or additional metals can be included in the intermediate barriermetal, such as, but not limited to, aluminum, chromium, cobalt,molybdenum, Sn—Ni, Fe—Ni, tin, and/or zinc. Typically, one intermediatebarrier metal is formed on the surface of the base metal; however, morethan one layer of one or more intermediate barrier metals can be appliedto the surface of the base metal to form a thicker intermediate barriermetal layer, alter the composition of the intermediate barrier metallayer, alter the composition of the heat created intermetallic layer ifformed, and/or improve the bonding of the metal alloy coating to theintermediate barrier metal layer and/or base metal. In one embodiment ofthe invention, copper or a copper alloy is included in the intermediatebarrier metal. A copper or copper alloy containing intermediate barriermetal layer enhances the corrosion-resistant properties of the heatcreated intermetallic layer that is formed between the metal alloy andthe base metal, improves the bonding of the metal alloy to the basemetal, and/or improves the corrosion resistance of the metal alloyand/or coated base metal. The copper or copper alloy in the intermediatebarrier metal can also inhibit adverse zinc crystal growth in the heatcreated intermetallic layer. A thick zinc layer can cause poor coatingquality or cracking of the coating during forming and bending, give riseto localized corrosion, and/or adversely affect performance of thecoated base metal in some applications. The copper or copper alloy istypically plated onto the surface of the base metal; however, the copperor copper alloy can be applied to the surface of the base metal by othermeans such as, but not limited to, hop dip coating, cladding or otherbonding methods. In one aspect of this embodiment, the copper or copperalloy is plated on the surface of the base metal. The plated copper orcopper alloy layer can be formed by passing the base metal through anelectroplating process or by adding copper sulfate to a picklingsolution and pickling the coated base metal. In another and/oralternative embodiment of the invention, the intermediate barrier metalincludes nickel. Typically, the nickel is flashed or plated to the basemetal surface; however, the nickel can be applied to the surface of thebase metal by other means. The nickel in the intermediate barrier metallayer improves corrosion-resistance of the base metal and/or metalalloy, especially against halogen containing compounds which canpenetrate the metal alloy coating and attack and oxidize the surface ofthe base metal thereby weakening the bond between the base metal and themetal alloy coating. The nickel in the intermediate barrier metal layerhas also been found to provide a formidable barrier to alcohols and/orvarious type of petroleum products. The metal alloy coating and nickelin the intermediate barrier metal can effectively complement one anotherto provide superior corrosion resistance. An intermediate barrier metallayer which includes nickel can also improve the bonding of the metalalloy coating to the base metal. An intermediate barrier metal layerwhich includes nickel can also inhibit the formation of a thick zinclayer in the heat created intermetallic layer. In yet another and/oralternative embodiment of the invention, the thickness of theintermediate barrier metal layer is at least about 0.3 micron. In oneaspect of this embodiment, the thickness of the intermediate barriermetal layer is at least about 1 micron. In another and/or alternativeaspect of this embodiment, the thickness of the intermediate barriermetal layer is less than about 500 microns. In yet another and/oralternative aspect of this embodiment, the thickness of the intermediatebarrier metal layer is less than about 250 microns. In still anotherand/or alternative aspect of this embodiment, the thickness of theintermediate barrier metal layer is less than about 50 microns. In stillyet another and/or alternative aspect of this embodiment, the thicknessof the intermediate barrier metal layer is less than about 20 microns.In a further and/or alternative aspect of this embodiment, the thicknessof the intermediate barrier metal layer is about 1-15 microns. In yet afurther and/or alternative aspect of this embodiment, the thickness ofthe intermediate barrier metal layer is about 1-12 microns. Inaccordance with still yet another and/or alternative embodiment of theinvention, the intermediate barrier metal layer is heated prior toapplying the metal alloy coating to the base metal. The heating of theintermediate barrier metal layer to a sufficient temperature for asufficient amount of time causes a heat created intermetallic layer toform between the intermediate barrier metal layer and the base metal. Aheat created intermetallic layer can be formed without the use of asubsequent heating step when the intermediate barrier metal is appliedto the base metal by a metal spraying process, a coating roller process,and/or an immersion process. The temperature of the intermediate barriermetal in the heated or molten state causes a heat created intermetalliclayer to at least partially form between the intermediate barrier metaland the base metal. A “heat created intermetallic layer” is definedherein as a metal layer formed by heat wherein the metal layer is amixture of at least the primary surface components of the base metal andcomponents of a coated metal layer (i.e. intermediate barrier metaland/or metal alloy coating). The application of heat to the base metaland the coated metal layer results in the surface of the base metal tosoften and/or melt, and to combine with a portion of the soften ormelted coated metal layer. In many instances, the formation of a heatcreated intermetallic layer results in improved bonding of the coatedmetal layer to the base metal, and/or improves the corrosion-resistanceof the base metal and/or coated metal layer. Typically the temperaturethat the coated metal layer and/or base metal is exposed to at leastpartially cause the formation of a heat created intermetallic layer is atemperature that at least softens the surface of the base metal and/orthe coated metal layer. In many instances, the melting point of thecoated metal layer will be less than the melting temperature of thesurface of the base metal. As such, the temperature that the coatedmetal layer and/or base metal is exposed to is typically the temperaturethat at least softens the coated metal layer. For example, if the coatedmetal layer was plated copper, the temperature needed to at leastpartially cause the formation of a heat created intermetallic layerwould be at least about 926° C. (1700° F.), and typically at least about1060° C. (1940° F.). In one aspect of this embodiment, the thickness ofthe heat created intermetallic layer formed between the base metal andthe intermediate barrier metal is at least about 0.1 micron. In anotherand/or alternative aspect of this embodiment, the thickness of the heatcreated intermetallic layer formed between the base metal and theintermediate barrier metal is at least about 0.3 micron. In stillanother and/or alternative aspect of this embodiment, the thickness ofthe heat created intermetallic layer formed between the base metal andthe intermediate barrier metal is at least about 0.5 micron. In yetanother and/or alternative aspect of this embodiment, the thickness ofthe heat created intermetallic layer formed between the base metal andthe intermediate barrier metal is at least about 1 micron. In still yetanother and/or alternative aspect of this embodiment, the thickness ofthe heat created intermetallic layer formed between the base metal andthe intermediate barrier metal is less than about 100 microns. In stillyet another and/or alternative aspect of this embodiment, the thicknessof the heat created intermetallic layer formed between the base metaland the intermediate barrier metal is less than about 50 microns. In afurther and/or alternative aspect of this embodiment, the thickness ofthe heat created intermetallic layer formed between the base metal andthe intermediate barrier metal is less than about 25 microns. In yet afurther and/or alternative aspect of this embodiment, the thickness ofthe heat created intermetallic layer formed between the base metal andthe intermediate barrier metal is less than about 20 microns. In still afurther and/or alternative aspect of this embodiment, the thickness ofthe heat created intermetallic layer formed between the base metal andthe intermediate barrier metal is less than about 18 microns. In stillyet a further and/or alternative aspect of this embodiment, thethickness of the heat created intermetallic layer formed between thebase metal and the intermediate barrier metal is about 1-15 microns. Inanother and/or alternative aspect of this embodiment, the thickness ofthe heat created intermetallic layer formed between the base metal andthe intermediate barrier metal is about 2-15 microns. In still anotherand/or alternative aspect of this embodiment, the thickness of the heatcreated intermetallic layer formed between the base metal and theintermediate barrier metal is about 2-12 microns. Typically theformation of a heat created intermetallic layer takes at least a coupleseconds to form. In still another and/or alternative embodiment of thepresent invention, the base metal is exposed to heat for at least about2 seconds to at least partially form the heat created intermetalliclayer between the base metal and the intermediate barrier metal. Thetime period of heat exposure for an intermediate barrier metal layerapplied by a plating and/or a pickling process is the time theintermediate barrier metal is exposed to heat after the plating and/orpickling process. The time period for heat exposure for an intermediatebarrier metal layer applied by metal spraying, coating rollers, and/orimmersion in molten metal includes the time of applying the intermediatebarrier metal to the base metal and the time the intermediate barriermetal is exposed to heat after the metal spraying, coating rollers,and/or immersion in molten metal process. Typically, the time of totalheat exposure is less than about four hours; however, greater heatexposure times can be used. In one aspect of this embodiment, the totaltime period of heat exposure to an intermediate barrier metal layerapplied to the base metal to at least partially form an intermetalliclayer between the base metal and the intermediate barrier metal layer isless than about 20 minutes. In another and/or alternative aspect of thisembodiment, the total time period of heat exposure to an intermediatebarrier metal layer applied to the base metal to at least partially forman intermetallic layer between the base metal and the intermediatebarrier metal layer is less than about 10 minutes. In yet another and/oralternative aspect of this embodiment, the total time period of heatexposure to an intermediate barrier metal layer applied to the basemetal to at least partially form an intermetallic layer between the basemetal and the intermediate barrier metal layer is less than about 5minutes. In still another and/or alternative aspect of this embodiment,the total time period of heat exposure to an intermediate barrier metallayer applied to the base metal to at least partially form anintermetallic layer between the base metal and the intermediate barriermetal layer is about 0.033-2 minutes. When heat is applied to the coatedbase metal to form or further form the heat created intermetallic layerbetween the base metal and intermediate metal barrier layer, the heattypically is applied by, but not limited to, an oven and/or furnace,induction heating coils, lasers, heat exchanger, and/or radiation. Ascan be appreciated, the flow heating of the plated intermediated barrierlayer can also function as a pre-heat process for the base metal.Alternatively, or in addition to, the heat can be supplied by coatingthe base metal and the intermediated metal barrier layer with a metalalloy by a hot-dip process. The heat from the hot-dip process causes theformation of the heat created intermetallic layer. In still anotherembodiment of the invention, the application of the intermediate barriermetal layer on the surface of the base metal is a partial or completepretreatment process for the surface of the base metal prior to applyingthe metal alloy coating to the base metal. The application of the anintermediate barrier metal to the surface of the base metal forms aclean metal surface on the base metal surface. Due to this clean metalsurface, the application of the an intermediate barrier metal to thesurface of the base metal can function as the sole pretreatment processfor the surface of the base metal. As can be appreciated, the surface ofthe base metal can be pretreated with other pretreatment process priorto applying the intermediate barrier metal layer and/or pretreated withother pretreatment process subsequent to applying the intermediatebarrier metal layer.

[0052] In accordance with another and/or alternative aspect of theinvention, metal alloy coating is coated on the base metal by a platingprocess or by a hot dip process. The coating process for the metal alloycoating can be by a batch or continuous process. As defined herein, a“hot dip process” for the metal alloy is any process that coats themetal alloy coating on the base metal and causes the at least partialformation of a heat created intermetallic layer between the base metaland the metal alloy coating. Examples of a hot dip process include, butare not limited to, 1) plating a metal alloy coating partially ortotally on the base metal and subsequently heating the plated layeruntil a heat created intermetallic layer at least partially formsbetween the plated layer and the base metal, 2) plating a metal alloypartially or totally on the base metal and subsequent partial or totalimmersion of the base metal in a molten bath of metal alloy for asufficient period of time to partially or totally coat the base metaland to at least partially form a heat created intermetallic layerbetween the coated metal alloy layer and the base metal, 3) plating ametal alloy partially or totally on the base metal and subsequent spraycoating molten metal alloy onto the base metal to partially or totallycoating the base metal wherein the base metal is spray coated for asufficient period of time to at least partially form a heat createdintermetallic layer between the coated metal layer and base metal, 4)plating a metal alloy partially or totally on the base metal andsubsequent partial or total immersion of the base metal in a molten bathof metal alloy and spray coating molten metal alloy onto the base metalto partially or totally coat the base metal wherein the base metal isspray coated and immersed for a sufficient period of time to at leastpartially form a heat created intermetallic layer between the coatedmetal layer and base metal, 5) partial or total immersion of the basemetal in a molten bath of metal alloy for a sufficient period of time topartially or totally coat the base metal and to at least partially forma heat created intermetallic layer between the coated metal layer andthe base metal, 6) partial or total immersion of the base metal in amolten bath of metal alloy for a sufficient period of time to partiallyor totally coat the base metal and spray coating molten metal alloy ontothe base metal to partially or totally coat the base metal wherein thebase metal is immersed and sprayed for a sufficient period of time to atleast partially form a heat created intermetallic layer between thecoated metal layer and base metal, 7) spray coating the base metal withmolten metal alloy to partially or totally coat the base metal for asufficient period of time to at least partially form a heat createdintermetallic layer between the coated metal layer and the base metal,8) plating and subsequent heating and subsequent immersion in moltenmetal alloy coating and/or spray coating molten metal alloy coating toat least partially form a heat created intermetallic layer between thecoated metal layer and the base metal, 9) plating and subsequent heatingand subsequent immersion in molten metal alloy coating and/or spraycoating molten metal alloy coating and subsequent heating afterimmersion in molten metal alloy coating and/or spray coating moltenmetal alloy coating to at least partially form a heat createdintermetallic layer between the coated metal layer and the base metal,10) immersion in molten metal alloy coating and subsequent heating to atleast partially form a heat created intermetallic layer between thecoated metal layer and the base metal, 11) immersion in molten metalalloy coating and spray coating molten metal alloy coating andsubsequent heating after immersion and spray coating to at leastpartially form a heat created intermetallic layer between the coatedmetal layer and the base metal, 12) spray coating molten metal alloycoating and subsequent heating after spray coating to at least partiallyform a heat created intermetallic layer between the coated metal layerand the base metal, 13) coating molten metal alloy by coating rollers toat least partially form a heat created intermetallic layer between thecoated metal layer and the base metal, 14) coating molten metal alloy bycoating rollers and spray coating to at least partially form a heatcreated intermetallic layer between the coated metal layer and the basemetal, 15) immersion in molten metal alloy and coating molten metalalloy by coating rollers to at least partially form a heat createdintermetallic layer between the coated metal layer and the base metal,16) plating and coating molten metal alloy by coating rollers to atleast partially form a heat created intermetallic layer between thecoated metal layer and the base metal, and 17) coating molten metalalloy by coating rollers and subsequent heating to at least partiallyform a heat created intermetallic layer between the coated metal layerand the base metal. As can be appreciated, many other hot dip coatingcombinations can be used. As further can be appreciated, the base metalcan be coated a multiple of times by various types of coated processes.When heat is applied to the coated base metal to form or further formthe heat created intermetallic layer between the base metal and themetal alloy coating, the heat typically is applied by, but not limitedby, an oven and/or furnace, induction heating coils, lasers, heatexchanger, and/or radiation. In one embodiment of the invention, thethickness of the heat created intermetallic layer is at least about 0.3micron. In one aspect of this embodiment, the thickness of the heatcreated intermetallic layer formed between the base metal and the metalalloy coating is at least about 1 micron. In yet another and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 100 microns. In still another and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 50 microns. In still yet another and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 25 microns. In a further and/or alternativeaspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 20 microns. In still a further and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 18 microns. In still yet a further and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is about 1-15 microns. In another and/or alternative aspect ofthis embodiment, the thickness of the heat created intermetallic layerformed between the base metal and the metal alloy coating is about 2-15microns. In still another and/or alternative aspect of this embodiment,the thickness of the heat created intermetallic layer formed between thebase metal and the metal alloy coating is about 2-12 microns. Typically,the formation of a heat created intermetallic layer takes at least acouple seconds to form. In another and/or alternative embodiment of theinvention, the base metal and/or metal alloy coating is exposed to heatfor at least 2 seconds to at least partially form the heat createdintermetallic layer between the base metal and the metal alloy coating.The time period of heat exposure of a metal alloy coating layer appliedby a plating process is the time the metal alloy coating is exposed toheat after the plating process. The time period for heat exposure for ametal alloy coating layer applied by metal spraying, coating rollersand/or immersion in molten metal includes the time of applying the metalalloy coating to the base metal and the time the metal alloy coating isexposed to heat after the metal spraying, coating rollers, and/orimmersion in molten metal process. In one aspect of this embodiment, thetotal time period of heat exposure to a metal alloy coating layerapplied to the base metal to at least partially form an intermetalliclayer between the base metal and the metal alloy coating layer is lessthan about 4 hours; however, greater heat exposure times can be used. Inanother and/or alternative aspect of this embodiment, the total timeperiod of heat exposure to a metal alloy coating layer applied to thebase metal to at least partially form an intermetallic layer between thebase metal and the metal alloy coating layer is less than about 3 hours.In still another and/or alternative aspect of this embodiment, the totaltime period of heat exposure to a metal alloy coating layer applied tothe base metal to at least partially form an intermetallic layer betweenthe base metal and the metal alloy coating layer is less than about 2hours. In yet another and/or alternative aspect of this embodiment, thetotal time period of heat exposure to a metal alloy coating layerapplied to the base metal to at least partially form an intermetalliclayer between the base metal and the metal alloy coating layer is lessthan about 1 hour. In still yet another and/or alternative aspect ofthis embodiment, the total time period of heat exposure to a metal alloycoating layer applied to the base metal to at least partially form anintermetallic layer between the base metal and the metal alloy coatinglayer is less than about 30 minutes. In a further and/or alternativeaspect of this embodiment, the total time period of heat exposure to ametal alloy coating layer applied to the base metal to at leastpartially form an intermetallic layer between the base metal and themetal alloy coating layer is less than about 20 minutes. In yet furtherand/or alternative aspect of this embodiment, the total time period ofheat exposure to a metal alloy coating layer applied to the base metalto at least partially form an intermetallic layer between the base metaland the metal alloy coating layer is less than about 10 minutes. Instill a further and/or alternative aspect of this embodiment, the totaltime period of heat exposure to a metal alloy coating layer applied tothe base metal to at least partially form an intermetallic layer betweenthe base metal and the metal alloy coating layer is less than about 5minutes. In still yet further and/or alternative aspect of thisembodiment, the total time period of heat exposure to a metal alloycoating layer applied to the base metal to at least partially form anintermetallic layer between the base metal and the metal alloy coatinglayer is about 0.033-2 minutes. In another and/or alternative aspect ofthis embodiment, the total time period of heat exposure to a metal alloycoating layer applied to the base metal to at least partially form anintermetallic layer between the base metal and the metal alloy coatinglayer is about 0.033-0.5 minutes. In yet another and/or alternativeaspect of this embodiment, the total time period of heat exposure to ametal alloy coating layer applied to the base metal to at leastpartially form an intermetallic layer between the base metal and themetal alloy coating layer is about 0.083-0.5 minutes. In still yetanother and/or alternative embodiment of the invention, the metal alloycoating formed on the surface of the base metal by a batch coatingprocess or by a continuous coating process can result in different typesof coatings. These differences can include, but are not limited to, thefollowing:

[0053] a) Uniformity of coating (weight and thickness)

[0054] b) Surface appearance

[0055] c) Smoothness

[0056] d) Texture control

[0057] e) Control of intermetallic phases (growth and uniformity)

[0058] A base metal coated in a continuous coating process typicallyproduces a coated base metal having superior uniformity of coating(weight and thickness), superior metallographic structure, superiorsurface appearance, superior smoothness, superior spangle size, andfewer surface defects. Furthermore, the composition of the heat createdintermetallic layer is typically superior as compared to a base metalcoated in a batch coating process. In addition to surface appearance anduniformity of thickness, the formability of the coated base metal isgenerally better due to a more uniform coating thickness on the surfaceof the base metal. In general, thicker coatings provide greatercorrosion protection, whereas thinner coatings tend to give betterformability and weldability. Thinner coatings with uniformity ofthickness can be better formed by a continuous coating process.

[0059] In still another and/or alternative aspect of the invention, themetal alloy coating is at least partially applied to the surface of thebase metal, the surface of the intermediate barrier metal layer, and/oran existing metal alloy coating by a plating process. When a platingprocess is used, a heat created intermetallic layer is not formedbetween the metal alloy coating and the surface of the base metal, thesurface of the intermediate barrier metal layer, and/or a previouslyapplied metal alloy coating. Typically, the plating process is carriedout by standard plating processes, thus a detailed description of aplating process is not described herein. The complete or partial surfaceof the base metal, the surface of the intermediate barrier metal layer,and/or surface of a previously applied metal alloy can be coated by theplating process. The plating of the components of the corrosionresistant metal alloy can be accomplished at the same time or insubsequent steps. For instance, a corrosion resistant tin and zinc alloywhich an be plated by a) simultaneously plating the tin and zinc ontothe surface of the base metal, the surface of the intermediate barriermetal layer, and/or metal alloy coating, b) first plating the tin on thesurface of the base metal, the surface of the intermediate barrier metallayer and/or metal alloy coating, and subsequently plating the zinc onthe surface of the base metal, the surface of the intermediate barriermetal layer, and/or metal alloy coating, or c) first plating the zinc onthe surface of the base metal, the surface of the intermediate barriermetal layer, and/or metal alloy coating, and subsequently plating thetin on the surface of the base metal, the surface of the intermediatebarrier metal layer, and/or metal alloy coating. Similarly, a corrosionresistant tin and zinc alloy which includes antimony can be plated by a)simultaneously plating the tin, zinc and antimony onto the surface ofthe base metal, the surface of the intermediate barrier metal layer,and/or metal alloy coating, b) first plating the tin on the surface ofthe base metal, the surface of the intermediate barrier metal layer,and/or metal alloy coating, then plating the zinc on the surface of thebase metal, the surface of the intermediate barrier metal layer, and/ormetal alloy coating, and subsequently plating the antimony on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or metal alloy coating, c) first plating the zinc on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or metal alloy coating, then plating the tin on the surfaceof the base metal, the surface of the intermediate barrier metal layer,and/or metal alloy coating, and subsequently plating the antimony on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or metal alloy coating, d) first plating the antimony on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or metal alloy coating, and subsequently simultaneouslyplating tin and zinc on the surface of the base metal, the surface ofthe intermediate barrier metal layer, and/or metal alloy coating, etc.In one embodiment of the invention, a tin and zinc alloy is plated onthe surface of the base metal. In one aspect of this embodiment, theplating process includes the plating of tin and zinc in an electrolyticsolution containing stannous tin, zinc and an acid.

[0060] In yet another and/or alternative aspect of the invention, themetal alloy coating is at least partially applied to the surface of thebase metal, the surface of the intermediate barrier metal layer, and/orpreviously applied metal alloy coating by a hot dip process thatincludes plating and subsequent heating of the plated metal alloy. Themetal alloy is plated onto the surface of the base metal, the surface ofthe intermediate barrier metal layer, and/or a previously applied metalalloy coating by a plating process that is the same as or similar to theplating process described above. After the metal alloy is plated ontothe surface of the base metal, the surface of the intermediate barriermetal layer, and/or previously applied metal alloy coating, the platedmetal alloy coating is subjected to heat for a sufficient period of timeand at a sufficient temperature to form a heat created intermetalliclayer between the plated metal alloy coating and the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating (i.e. flowheating). If one or more of the components of the corrosion resistantmetal alloy coating are plated by a separate plating process, the platedmetal components of the metal alloy coating can be subjected to heatafter one or more of the plating processes, or after all the componentsof the metal alloy coating have been coated onto the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating. The heating ofthe plated metal alloy coating causes at least a portion of the metalalloy to enter a softened or molten state and to form an at leastpartially uniform and substantially level coating layer. The heating ofthe plated metal alloy coating also facilitates in the reduction and/orelimination of pin holes in the metal alloy coating which may haveformed during the plating process. The time period selected for heatingthe plated metal alloy coating generally depends on the time necessaryto soften and/or melt the desired amount of metal coating to form thedesired thickness of the heat created intermetallic layer. When one ormore of the components of the metal alloy coating are plated by separateplating process, the plated metal components of the metal alloy coatingare subjected to heat for a sufficient period of time to at leastpartially alloy together the components of the metal alloy coating. Theheating process for the plated metal alloy can be by a batch or by acontinuous process. In one embodiment of the invention, the plated metalalloy coating is exposed to heat by the application of another moltenmetal alloy coating onto the surface of the plated metal alloy coating.The heat of the molten metal alloy upon contact with the plated metalalloy causes the components of the plated metal alloy coating to atleast partially alloy together and/or to at least partially form theheat created intermetallic layer between the plated metal alloy coatingand the surface of the base metal, the surface of the intermediatebarrier metal layer, and/or the surface of the previously applied metalalloy coating. In one aspect of this embodiment, a molten metal alloy isapplied by immersion and coated onto the surface of the plated metalalloy coating. In another aspect of this embodiment, a molten metalalloy is applied by coating rollers and coated onto the surface of theplated metal alloy coating. In still another aspect of this embodiment,a molten metal alloy is applied by spray coating and coated onto thesurface of the plated metal alloy coating. In another embodiment of theinvention, the plated metal alloy coating is exposed to an external heatsource for a time period and temperature sufficient to at leastpartially alloy together the components of the plated metal alloycoating and/or to at least partially form the heat created intermetalliclayer between the plated metal alloy coating and the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating. The plated metalalloy coating is typically exposed to heat through the use of aconvection oven, a furnace, heated fluids, flames, induction heating,lasers, hot gasses, radiation, and the like. In one aspect of thisembodiment, the temperature the plated metal alloy is exposed to atemperature that is at least about 200° C. In another aspect of thisembodiment, the temperature the plated metal alloy is exposed to atemperature that is less than about 2000° C. In still another aspect ofthis embodiment, the temperature the plated metal alloy is exposed to isless than about 1000° C. In yet another aspect of this embodiment, thetemperature that the plated metal alloy is exposed to is less than about500° C.

[0061] In accordance with still yet another and/or alternative aspect ofthe invention, the corrosion resistant metal alloy is at least partiallycoated onto the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by immersion into molten corrosion resistantmetal alloy. In one embodiment of the invention, the molten corrosionresistant metal alloy is maintained at a temperature of at least about232° C. (449° F.). In one aspect of this embodiment, the moltencorrosion resistant metal alloy is maintained at a temperature of atleast about 2-30° C. above the melting point of the corrosion resistantmetal alloy. In another embodiment of the invention, the residence timeof the base metal in the molten corrosion resistant alloy is selected toat least partially form a heat created intermetallic layer between thecorrosion resistant alloy metal coating and the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating. In one aspect ofthis embodiment, the residence time of the base metal in the moltenmetal alloy is at least about 0.033-0.083 minutes. In another aspect ofthis embodiment, the residence time of the base metal in the moltenmetal alloy is less than about 10 minutes. In still another aspect ofthis embodiment, the residence time of the base metal in the moltenmetal alloy is less than about two minutes. In yet another aspect ofthis embodiment, the residence time of the base metal in the moltenmetal alloy is less than about one minute. In still yet another aspectof this embodiment, the residence time of the base metal in the moltenmetal alloy is about 0.083-0.5 minutes.

[0062] In accordance with another and/or alternative aspect of theinvention, the hot dip coating of the base metal by immersion in moltenmetal alloy includes the use of a flux box. The flux box is designed toreceive the base metal prior to the base metal passing into the moltenmetal alloy. The flux solution in the flux box can be formulated toremove residual oxides from the base metal surface; shield the surfaceof the base metal, the surface of the intermediate barrier metal layer,and/or the surface of the previously applied metal alloy coating fromoxygen until the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating base metal is coated with the molten metalalloy; inhibit the formation of viscous oxides at the point where thebase metal enters the molten metal alloy; and/or inhibit dross formationduring the coating process. The exposure of the base metal to the fluxsolution is typically the last pretreatment process of the base metalprior to being coated by immersion in molten metal alloy. In oneembodiment of the invention, the flux box contains a flux solution whichhas a lower specific gravity than the molten metal alloy, thus the fluxsolution at least partially floats on the surface of the molten alloy.In another and/or alternative embodiment of the invention, the fluxsolution includes a zinc chloride solution. In one aspect of thisembodiment, the flux solution includes ammonium chloride. In anotherand/or alternative aspect of this embodiment, the flux solution includesabout 20-75% by volume zinc chloride. In yet another and/or alternativeaspect of this embodiment, the flux solution includes zinc chloride andammonium chloride. In still yet another and/or alternative aspect ofthis embodiment, the flux solution includes about 20-75% by volume zincchloride and up to about 40% by volume ammonium chloride. In a furtherand/or alternative aspect of this embodiment, the flux solution includesabout 30-60% by volume zinc chloride and up to about 1-20% by volumeammonium chloride. In yet a further and/or alternative aspect of thisembodiment, the flux solution includes about 50% by volume zinc chlorideand about 8% by volume ammonium chloride.

[0063] In accordance with still another and/or alternative aspect of theinvention, the hot dip process of coating the base metal is by immersionin a molten metal alloy includes a melting pot for heating the moltenmetal alloy. In one embodiment of the invention, the melting pot isheated by heating coils, heating rods, gas jets, induction heating,lasers, radiation, etc. In one aspect of this embodiment, the meltingpot is heated by at least one gas jet directed toward at least one sideof the melting pot. In another and/or alternative aspect of thisembodiment, heating coils and heating rods are used to heat the metalalloy directly in the melting pot. In still another and/or alternativeaspect of this embodiment, gas jets are used heat the molten metal alloyin the melting pot.

[0064] In accordance with a further and/or alternative aspect of theinvention, the hot dip process of coating the base metal by immersion inmolten metal alloy includes the use of a protective material on at leasta portion of the surface of the molten metal alloy in the melting pot.The protective material is formulated to at least partially shield themolten metal alloy from the atmosphere thereby preventing or inhibitingoxide formation on the surface of the molten metal alloy, and/orpreventing or inhibiting dross formation on the coated base metal as thecoated base metal enters and/or exits from the melting pot. In oneembodiment of the invention, the protective material has a specificgravity which is less than the specific gravity of the molten metalalloy so that at least a portion of the protective material at leastpartially floats on the surface of the molten metal alloy. In anotherand/or alternative embodiment of the invention, the protective materialincludes an oil. In one aspect of this embodiment, the protectivematerial includes palm oil. When the protective material is palm oil,the melting point of the metal alloy should be below about 344° C., thedegrading point of palm oil. For metal alloys having a higher meltingpoint, other oils, fluxes, or other materials and/or special coolingprocesses for the protective material are employed when a protectivematerial is used. In still another and/or alternative embodiment, theprotective material facilitates in forming a smooth and uniform coatingon the surface of the base metal.

[0065] In accordance with another and/or alternative aspect of theinvention, the thickness of the metal alloy coating by immersion inmolten metal alloy is at least partially regulated by the residence timeof the base metal in the molten metal alloy, the temperature of themolten metal alloy in the melting pot, and/or the speed at which thebase metal moves through the molten metal alloy. In one embodiment ofthe invention, the base metal is maintained at a substantially constantspeed through the molten metal alloy. The substantially uniform speedresults in a substantially uniform growth of the heat createdintermetallic layer between the metal alloy and the base metal, asubstantially smooth coating of metal alloy, and/or a substantiallyconstant metal alloy coating thickness. As the base metal passes throughthe molten metal alloy at a substantially constant speed, the metalalloy adheres to the moving base metal and shears a portion of the metalalloy coating from the moving base metal. The shearing effect resultsfrom the viscosity of the molten alloy and the speed of the moving basemetal. For a given speed and metal alloy viscosity, a certain thicknessof metal alloy will be applied to the base metal over a given time. Theshearing effect results in a substantially uniform coating, excellentsurface appearance, excellent smoothness, excellent texture control anda substantially uniform heat created intermetallic layer. In anotherand/or alternative embodiment of the invention, the base metal is coatedby moving the base metal through the molten metal alloy in the meltingpot at a relatively constant speed of about 1-400 ft/min. In one aspectof this embodiment, the base metal is moved through the molten metalalloy in the melting pot at a relatively constant speed of about 50-250ft/min.

[0066] In accordance with still another and/or alternative aspect of theinvention, the corrosion resistant metal alloy is at least partiallycoated onto the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by a coating roller process. Molten metalalloy on the coating rollers is applied to the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating by a coatingroller process as the base metal passes by or between one or morecoating rollers. The coating rollers form a substantially smooth and/oruniform metal alloy coating layer on the base metal. One or more coatingrollers at least partially press against and coat the surface of thebase metal, the surface of the intermediate barrier metal layer, and/orthe surface of the previously applied metal alloy coating; and/or fillpin holes or uncoated surfaces on the surface of the base metal, thesurface of the intermediate barrier metal layer, and/or the surface ofthe previously applied metal alloy coating by a coating roller process.The coating rollers can also control the thickness of the metal alloycoating onto the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by a coating roller process. In oneembodiment of the invention, one or more coating rollers are used inconjunction with an immersion process and/or metal spray process. Inanother and/or alternative embodiment, at least two coating rollers arespaced apart a sufficient distance so that the base metal can passbetween the coating rollers. As the base metal basses between one ormore coating rollers, the coating rollers maintain a desired coatingthickness of the metal alloy on the base metal, remove excess metalalloy from the base metal, and/or coat any non-coated regions on thesurface of the base metal. In one aspect of this embodiment, the coatingthickness of the metal alloy is selected to ensure that essentially nouncoated regions exist on the surface of the base metal. Typically, thethickness of the metal alloy on the surface of base metal is at leastabout 1 micron, and generally at least about 2.5 microns, more generallyabout 7 to 2550 microns, and even more generally about 7-1270 microns.In another and/or alternative aspect of this embodiment, the coatingthickness of the metal alloy is selected to ensure the coated metalalloy has essentially no pin holes, and/or does not shear when formedinto various products. A metal alloy coating thickness of about 25-51microns forms a coating that has few, if any, pin holes, providesgreater elongation characteristics, and resist shearing when formed intovarious shaped articles; however, thinner coating may include few, ifany, pin holes. In still another and/or alternative aspect of thisembodiment, the thickness of the metal alloy is selected for use incertain types of environments in which the coated base metal is to beused. A metal alloy coating thickness of about 25-51 microns forms acoating that significantly reduces the corrosion rate of the base metalin virtually all types of environments; however, thinner coatings cansignificantly reduces the corrosion rate of the base metal. Metal alloycoating thicknesses greater than about 51 microns are typically used inharsh environments to provide added corrosion protection. In yet anotherand/or alternative embodiment of the invention, the molten metal alloyis maintained at a temperature at least about 2-30° C. above the meltingpoint of the metal alloy, while the metal alloy is on the coatingrollers. In still yet another and/or alternative embodiment of theinvention, the coating process includes at least one set of coatingrollers that partially or fully coat the surface of the base metal asthe base metal passes the coating rollers. In a further and/oralternative embodiment of the invention, one or more coating rollers areat least partially immersed in molten metal alloy during the coatingprocess. In one aspect of this embodiment, the coating process is usedin conjunction with an immersion coating process and one or more of thecoating rollers are at least partially immersed in molten metal alloy inthe melting pot. In another and/or alternative aspect of thisembodiment, one or more of the coating rollers are at least partiallyimmersed in a protective material in the melting pot. In yet a furtherand/or alternative embodiment of the invention, one or more coatingrollers are positioned above the molten metal alloy in the melting potwhen the coating rollers are used in conjunction with an immersioncoating process. In still a further and/or alternative embodiment of theinvention, one or more coating rollers are at least partially coatedwith molten metal alloy by one or more spray jets that directs moltenmetal alloy on to the one or more coating rollers. The one or more sprayjets at least partially direct the molten metal alloy on to the surfaceof the coating rollers as the base metal passes by or between thecoating rollers thereby resulting in the base metal being partially orcompletely coated with the metal alloy. In still a further and/oralternative embodiment of the invention, one or more coating rollersinclude an internal cavity in which molten metal alloy is directed intoand then directed onto the surface of the coating roller which at leastpartially directs the molten metal alloy on to the surface of thecoating rollers as the base metal passes by or between the coatingrollers. In still yet a further and/or alternative embodiment of theinvention, the time period the base metal is exposed to each coatingroller is a relatively short time. The time period is dependent on thespeed of the base metal and the size of the coating rollers. Typically,the base metal is exposed to the coating rollers for at least about 0.3seconds and generally about 0.5-30 seconds. In another and/oralternative embodiment of the invention, one or more coating rollersinclude one or more grooves. The one or more grooves are designed tofacilitate in maintaining the molten metal alloy on the coating rollerduring the coating process.

[0067] In accordance with yet another and/or alternative aspect of thepresent invention, the corrosion resistant metal alloy is at leastpartially coated onto the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by a spray coating process. Molten metalalloy is sprayed onto the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by one or more spray jets. The spray jetsspray molten metal alloy onto the surface of the base metal, the surfaceof the intermediate barrier metal layer, and/or the surface of thepreviously applied metal alloy coating to at least partially coat thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or the surface of the previously applied metal alloy coating,and/or ensure that a uniform and/or continuous coating is applied on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or the surface of the previously applied metal alloy coating.The speed and time the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy is in contact with the molten metal can becontrolled so that the desired coating thickness and/or desiredthickness of the heat created intermetallic layer is obtained. In oneembodiment of the invention, the spray jets are used in conjunction withcoating rollers and/or an immersion process. In one aspect of thisembodiment, the spray jets at least partially direct molten metal alloyonto the coating rollers and/or onto the surface of the base metal, thesurface of the intermediate barrier metal layer, and/or the surface ofthe previously applied metal alloy coating during the coating process.In another and/or alternative embodiment of the invention, the moltenmetal alloy is maintained at a temperature of at least about 2-30° C.above the melting point of the metal alloy as the metal alloy is sprayedfrom the one or more spray jets. In yet another and/or alternativeembodiment of the invention, the base metal passes by or between one ormore metal spray jets during the coating process to partially orcompletely coat the surface of the base metal. In still another and/oralternative embodiment of the invention, the base metal is exposed tothe molten metal alloy from the one or more metal spray jets for asufficient time to partially or fully coat the surface of the basemetal. The time the base metal is exposed to the molten metal alloy fromthe metal spray jets is dependent on the speed of the moving base metal.Typically, the base metal is exposed to the molten metal alloy from themetal spray jets for at least about 0.3 seconds, generally about 0.5-60seconds, and typically about 1-30 seconds.

[0068] In accordance with another and/or alternative aspect of thepresent invention, the coated base metal which is coated by a hot dipprocess is subjected to an air-knife process. In an air-knife process,the coated metal alloy is subjected to a high velocity fluid. The highvelocity fluid removes surplus molten corrosion resistant metal alloycoating from the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating; smears the coated corrosion resistant metalalloy over the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating thereby reducing or eliminating pin holes orother uncoated surfaces; improves the grain size of the coated metalalloy; smooths and/or reducing lumps or ribs in the coated metal alloy;reduces the metal alloy coating thickness; and/or cools and/or hardensthe molten metal alloy. In one embodiment of the invention, the airknife process uses a high velocity fluid which generally does notoxidize the corrosion resistant alloy. In one aspect of this embodiment,the fluid used in the air-knife process includes, but is not limited to,an inert or substantially inert gas such as, but not limited to,nitrogen, sulfur hexafluoride, carbon dioxide, hydrogen, noble gases,and/or hydrocarbons. In another and/or alternative embodiment of theinvention, the high velocity fluid of the air-knife process is directedonto both sides of the coated base metal and at a direction which is notperpendicular to the surface of the coated base metal. In still anotherand/or alternative embodiment of the invention, the protective materialon the surface of the molten metal alloy in the melting pot iseliminated when the air-knife process is used in conjunction with acoating process by immersion in molten alloy. When an air-knife processis used in conjunction with coating by immersion, the inert orsubstantially inert fluid inhibits or prevents dross formation and/orviscous oxide formation in the region in which the inert orsubstantially inert fluid contacts the molten metal alloy in the meltingpot. The high velocity of the inert or substantially inert fluid alsobreaks up and/or pushes away dross or viscous oxides on the surface ofthe molten metal alloy thus forming a dross and oxide free region forthe coated base metal to be removed from the melting pot. In yet anotherand/or alternative embodiment of the invention, the air-knife processincludes one or more blast nozzles to direct a high velocity fluidtoward the metal alloy coating on the surface of the base metal. In oneaspect of this embodiment, the coated base metal is directed between twoor more blast nozzles. In still yet another and/or alternativeembodiment, the air-knife process at least partially causes molten metalalloy on the surface of the base metal to be directed back into themelting pot when the air-knife process is used in conjunction with animmersion coating process. In a further and/or alternative embodiment,one or more blast nozzles are adjustable so as to direct the highvelocity fluid at various angles onto the surface of the coated basemetal. In yet a further and/or alternative embodiment of the invention,one or more blast nozzles are partially or fully enclosed in a chamber,which chamber is designed to accumulate or trap at least a portion ofthe fluid after the fluid is directed toward the base metal. Theaccumulated fluid can then be recirculated back through the blastnozzles. In still a further and/or alternative embodiment of theinvention, the air-knife process is used to control the thickness and/orquality of the molten metal alloy coating. In still yet a further and/oralternative embodiment of the invention, the base metal is exposed tothe fluid from the air-knife process for a relatively short period oftime. The time the base metal is exposed to the fluid can be dependenton the speed of the moving base metal. Typically, the base metal isexposed to the fluid from the air-knife process for at least about 0.3seconds, generally about 0.5-60 seconds, and typically about 1-30seconds.

[0069] In accordance with another and/or alternative aspect of thepresent invention, the coated base metal is cooled by a cooling process.Typically the coated base metal is cooled after being coated by a hotdip coating process. The coated base metal can be cooled by sprayingwith and/or subjecting the coated base metal to a cooling fluid and/orimmersing the coated base metal in a cooling fluid. As previouslystated, when an air-knife process is used, the coated base metal can beat least partially cooled by the fluid from the air-knife process. Whenthe heated corrosion resistant metal alloy slowly cools, larger grainsizes and lower grain densities generally occur in the corrosionresistant metal alloy coating, and the corrosion resistant metal alloycoating typically forms a more reflective surface. When the heatedcorrosion resistant metal alloy rapidly cools, fine grain sizes and/orincreased grain densities occur in the corrosion resistant metal alloycoating, and the corrosion resistant metal alloy coating typically formsa less reflective surface than a slowly cooled corrosion resistant alloycoating. Small grain sizes and/or higher grain densities in thecorrosion resistant metal alloy coating typically result in a strongerbonding coating and greater corrosion resistance. In one embodiment ofthe invention, the cooling process is less than about two hours. In oneaspect of this embodiment, the cooling process is less than about onehour. In another and/or alternative aspect of this embodiment, thecooling process is less than 10 minutes. In still another and/oralternative aspect of this embodiment, the cooling process is less thanabout 5 minutes. In another and/or alternative embodiment of theinvention, a liquid or gas is jet sprayed onto the surface of the coatedbase metal to cool the metal alloy coating. In one aspect of thisembodiment, the cooling fluid is water. In another and/or alternativeaspect of this embodiment, the temperature of the cooling fluid is about15-95° C. In yet another and/or alternative aspect of this embodiment,the temperature of the cooling fluid is about 20-60° C. In yet anotherand/or alternative aspect of this embodiment, the temperature of thecooling fluid is about ambient temperature (20-28° C.). In still yetanother and/or alternative aspect of this embodiment, the coated basemetal is at least partially guided by a camel-back guide as the coatedbase metal is cooled by the spray jets. The camel-back guide is designedto minimize contact with the coated base metal thereby reducing theamount of metal alloy coating inadvertently removed from the base metal.In one aspect of this embodiment, the camel-back design allows coolingfluid to be applied to both sides of the coated base metal. In stillanother and/or alternative embodiment of the invention, the coated metalalloy is cooled by immersion in a cooling fluid. Typically, the coatedbase metal is directed into a cooling tank that contains a coolingfluid. In one aspect of this embodiment, the temperature of the coolingfluid in the cooling tank is maintained at a desired temperature by useof agitators, heat exchangers, and/or replenishment of cooling fluid. Inanother and/or alternative aspect of this embodiment, the temperature ofthe cooling fluid is about 15-95° C. In yet another and/or alternativeaspect of this embodiment, the temperature of the cooling fluid is about20-60° C. In yet another and/or alternative aspect of this embodiment,the temperature of the cooling fluid is about ambient temperature(20-28° C.). In still yet another and/or alternative aspect of thisembodiment, water is used as the cooling fluid. The oxygen in the watercan cause discoloration of the metal alloy coating thereby reducing thereflectiveness of the metal alloy coating. In a further and/oralternative embodiment of the invention, the metal alloy is cooled at asufficient rate so as to control the grain size of the zinc crystal. Inone aspect of this embodiment, the metal alloy is cooled at a rate suchthat there are no more than about 40 zinc crystals in the metal alloyhave a maximum dimension of over about 400 μm within a 0.25 mm² regionof the metal alloy. In one aspect of this embodiment, the metal alloy iscooled at a sufficient rate such that there are no more than about 30zinc crystals in the metal alloy have a maximum dimension of over about400 μm within a 0.25 mm² region of the metal alloy. In still anotherand/or alternative aspect of this embodiment, the metal alloy is cooledat a sufficient rate such that there are no more than about 20 zinccrystals in the metal alloy have a maximum dimension of over about 400μm within a 0.25 mm² region of the metal alloy. In yet another and/oralternative aspect of this embodiment, the metal alloy is cooled at asufficient rate such that there are no more than about 30 zinc crystalsin the metal alloy have a maximum dimension of over about 300 μm withina 0.25 mm² region of the metal alloy. In still yet another and/oralternative aspect of this embodiment, the metal alloy is cooled at asufficient rate such that there are no more than about 20 zinc crystalsin the metal alloy have a maximum dimension of over about 300 μm withina 0.25 mm² region of the metal alloy. In a further and/or alternativeaspect of this embodiment, the metal alloy is cooled at a sufficientrate such that there are no more than about 10 zinc crystals in themetal alloy have a maximum dimension of over about 300 μm within a 0.25mm² region of the metal alloy. In still a further and/or alternativeaspect of this embodiment, the metal alloy is cooled at a sufficientrate such that there are no more than about 10 zinc crystals in themetal alloy have a maximum dimension of over about 200 μm within a 0.25mm² region of the metal alloy.

[0070] In accordance with another and/or alternative aspect of theinvention, the coated base metal is passed through a leveler whereby thecoated metal alloy is molded about the base metal, and/or smoothed. Inone embodiment of the invention, a final coating thickness is obtainedby the leveler. In another and/or alternative embodiment of theinvention, the leveler includes a plurality of rollers. In yet anotherand/or alternative embodiment of the invention, the base metal ismaintained at a tension as it is passed through the leveler. In stillanother and/or alternative embodiment of the invention, the surfacecoarseness Ra of the metal alloy is less than about 5 μm. In one aspectof this embodiment, the surface coarseness Ra of the metal alloy is lessthan about 4 μm. In another and/or alternative aspect of thisembodiment, the surface coarseness Ra of the metal alloy is less thanabout 0.01-4 μm. In another and/or alternative aspect of thisembodiment, the surface coarseness Ra of the metal alloy is less thanabout 0.05-3 μm.

[0071] In accordance with yet another and/or alternative aspect of theinvention, the coated base metal is rolled into a coil for laterprocessing or use.

[0072] In accordance with still another and/or alternative aspect of theinvention, the coated base metal is sheared into specific length platesor strip for later use or immediate processing. In one embodiment of theinvention, a shearing device shears a continuously moving coated basemetal. In one aspect of this embodiment, the shearing device moves withthe moving coated base metal when shearing.

[0073] In accordance with still yet another and/or alternative aspect ofthe present invention, the heat created intermetallic layer formedbetween the metal alloy coating and the surface of the base metal,surface of the intermediate barrier metal layer, and/or surface of apreviously applied metal alloy coating is at least partially exposed.The exposed heat created intermetallic layer has been found, in somesituations, to provide excellent corrosion resistance in a number ofenvironments. The heat created intermetallic layer can be exposed bymechanical and/or chemical processes. In one embodiment of theinvention, at least a portion of the metal alloy coating is removed by amechanical process that includes, but is not limited to, grinding,melting, shearing and the like. In another and/or alternative embodimentof the invention, at least a portion of the metal alloy coating isremoved by a chemical process which includes, but is not limited to, anoxidation process. The oxidation process at least partially removes thecoated metal alloy and at least partially exposes the heat createdintermetallic layer. The oxidation process includes the use of anoxidizing solution. In one aspect of this embodiment, the oxidationsolution is selected to be autocatalytic in that the oxidation solutionremoves the metal alloy coating but does not or only very slowly removesthe heat created intermetallic layer. In another and/or alternativeaspect of this embodiment, the oxidation solution includes nitric acidand/or chromic acid. When nitric acid is included in the oxidationsolution, the nitric acid concentration is generally about 5-60% byvolume and typically about 10-25% by volume of the oxidation solution.In still another and/or alternative aspect of this embodiment, theoxidation solution includes copper sulfate. When copper sulfate isincluded in the oxidation solution, the copper sulfate is generally lessthan about 10% by volume, typically about 0.5-2% by volume of theoxidation solution, and more typically about 1% by volume of theoxidation solution. In yet another and/or alternative aspect of thisembodiment, the exposure of the coated base metal to the oxidationsolution in the oxidation process is generally less than about one hour;however, longer times can be used depending on the concentration andtemperature of the oxidation solution, the type of metal alloy, thethickness of the metal alloy, and/or the degree of desired exposure ofthe heat created intermetallic layer. In one non-limiting design of thisaspect, the exposure to the oxidation solution in the oxidation processis less than about ten minutes. In another and/or alternativenon-limiting design of this aspect, the exposure to the oxidationsolution in the oxidation process is less than about two minutes. Instill another and/or alternative non-limiting design of this aspect, theexposure to the oxidation solution in the oxidation process is about0.08-1.5 minutes. In a further and/or alternative aspect of thisembodiment, after a sufficient amount of the heat created intermetalliclayer is exposed by the oxidation solution, the oxidation solution isremoved from the base metal and/or the base metal is removed from theoxidation solution. In still a further and/or alternative aspect thisembodiment, the temperature of the oxidation solution is about 15-80° C.In one non-limiting design of this aspect this embodiment, thetemperature of the oxidation solution is about 30-80° C. In anotherand/or alternative non-limiting design of this aspect, the temperatureof the oxidation solution is about 15-60° C. In still another and/oralternative non-limiting design of this aspect, the temperature of theoxidation solution is about 12-62° C. In yet another and/or alternativenon-limiting design of this aspect, the temperature of the oxidationsolution is about 40-60° C. In still yet another and/or alternativenon-limiting design of this aspect, the temperature of the oxidationsolution is about 22-42° C. In a further and/or alternative design ofthis aspect, the temperature of the oxidation solution is about 32° C.In still yet a further and/or alternative aspect of this embodiment, theoxidation solution is at least partially rinsed off after theintermetallic layer is exposed. In still another and/or alternativeembodiment of the invention, one non-limiting method of at leastpartially removing the metal alloy coating is described in U.S. Pat. No.5,397,652, which is incorporated herein.

[0074] In accordance with another and/or alternative aspect of thepresent invention, the exposed heat created intermetallic layer is atleast partially passivated by a passivation process. The passivationprocess is designed to at least partially react with the heat createdintermetallic layer and to form a thin corrosion resistant layer. Thecorrosion resistant layer typically exhibits improved corrosionresistant properties, improved abrasion resistance, improved hardness,improved formality, resists cracking, and/or has less reflective coloras compared to a non-passified intermetallic layer. The passivationprocess includes the use of a passivation solution. In one embodiment ofthe invention, the passivation solution includes a nitrogen containingcompound. In another and/or alternative embodiment of the invention, thepassivation solution is the same as the oxidation solution, thus theoxidation/passivation solution removes the metal alloy to expose theheat created intermetallic layer and subsequently passifies the exposedheat created intermetallic layer to form the corrosion resistant layer.In one aspect of this embodiment, the oxidizing solution fully orsubstantially ceases to react with the intermetallic layer after thepassivation later is formed (auto-catalytic). In another and/oralternative embodiment of the invention, the coated base metal materialis at least partially passivated in a different tank from the oxidationsolution. In yet another and/or alternative embodiment of the invention,the oxidation solution and/or passivation solution is at least partiallyrinsed off the coated base metal after the formation of the passivationlayer. In still yet another and/or alternative embodiment of the presentinvention, the pacified intermetallic layer exhibits excellentformability characteristics. The formability of the base material havinga pacified intermetallic layer on the surface of the base material canexhibit improved formability characteristics. The improved formabilityis believed to be at least partially the result of the complete orpartial removal of the metal alloy from the surface of the basematerial. The removal of the metal alloy reduces the thickness of thetreated base material. In yet another and/or alternative embodiment ofthe invention, the thickness of the passivation layer is at least about0.1 micron. In one aspect of this embodiment, the thickness of thepassivation layer is about 0.1-5 microns. In another and/or alternativeaspect of this embodiment, the thickness of the passivation layer is upto about 1.5 microns.

[0075] In accordance with still another and/or alternative aspect of thepresent invention, the coated base metal is at least partially treatedwith a weathering agent to accelerate the weathering, discoloration ofthe surface of the metal alloy coating, and/or control the formation ofwhite rust on the surface of the metal alloy coating. In one embodimentof the invention, the weathering material is applied to the metal alloycoating to oxidize the metal alloy coating surface, reduce thereflectivity of the metal alloy coating, and/or discolor the metal alloycoating. In another ans/or alternative embodiment of the invention, theweathering material is an asphalt-based paint which causes acceleratedweathering of the metal alloy coating when exposed to the atmosphere.The asphalt-based paint decreases the weathering time of the metal alloycoating. In one aspect of this embodiment, the asphalt paint is apetroleum-based paint which includes asphalt, titanium oxide, inertsilicates, clay, carbon black or other free carbon and an anti-settlingagent. In another and/or alternative aspect of this embodiment, theasphalt-based paint is applied at a thickness to form a semi-transparentor translucent layer over the metal alloy coating. In one non-limitingdesign of this aspect, the thickness of the asphalt-based paint is about1-500 microns. In another and/or alternative non-limiting design of thisaspect, the thickness of the asphalt-based paint is about 6-150 microns.In still another and/or alternative non-limiting design of this aspect,the thickness of the asphalt-based paint is about 6-123 microns. In yetanother and/or alternative non-limiting design of this aspect, thethickness of the asphalt-based paint is about 12-50 microns. In stillyet a further and/or alternative non-limiting design of this aspect, thethickness of the asphalt-based paint is about 12-25 microns. In stillyet another and/or alternative embodiment of the invention, theweathering agent is at least partially dried by air drying and/or byheating lamps.

[0076] In accordance with yet another and/or alternative aspect of thepresent invention, the base metal coated with the metal alloy coating isimmediately formed, or formed at a manufacturing site, or formed at abuilding site. In one embodiment of the invention, the coated base metalis formed into roofing materials such as disclosed in, but not limitedto, gutter systems or roofing material which are illustrated in U.S.Pat. Nos. 4,987,716; 5001,881; 5,022,203; 5,259,166; and 5,301,474, allof which are incorporated herein by reference. In one aspect of thisembodiment, the roofing materials are formed on site. In another and/oralternative embodiment of the invention, the coated base metal is formedinto an automotive part such as, but not limited to, a gasoline tank. Inone aspect of this embodiment, the gasoline tank includes a first andsecond metal shell member. The two combined cavities of the shellmembers are combined to form an inner fuel receiving chamber which holdsfuel within the receptacle. The abutting peripheral edges of the shellmembers are joined together and sealed to maintain the fuel within theinner petroleum receiving chamber. The two shell members can be joinedin any of a number of ways that will securely prevent the shells fromseparating and petroleum from leaking from the interior chamber (i.e.welding, soldering and/or bonding the edges together). Such a fuel tankis illustrated in U.S. Pat. No. 5,455,122, which is incorporated hereinby reference. In one aspect of this embodiment, a tin-zinc coated basemetal is used to at least partially for the gasoline tank, and any otherreceptacle or component that is exposed to petroleum products. It hasbeen found that when a tin-zinc coating or a tin alloy that includes asignificant amount of zinc is applied to a copper or copper alloy basemetal, or a non-copper or non-copper alloy base metal that has a coppersurface (e.g., plated, clad, hot dipped, brazened, etc.), the zinc atleast partially migrates from the tin and zinc alloy or tin alloy andcombines with the copper to form a corrosion resistant copper-zinc heatcreated intermetallic layer. The layer above the heat createdintermetallic layer is primarily tin and the remaining zinc content ofthe original tin zinc alloy or tin alloy. It has been found that usingtin and zinc alloys or tin alloys containing about 5-65 zinc, a highlycorrosion resistant copper-zinc alloy and a upper layer that primarilyincludes tin and a number of zinc globules or fingers. The top coatingwhich primarily includes tin results in little, if any, oxidation of thetin. In the past, when zinc was exposed to petroleum products, the zincformed a white chalky surface layer. The upper layer of the presentinvention which primarily includes tin resists or prevents the formationof this white chalky surface layer. In addition, the copper-zincintermetallic layer provides added corrosion resistence in otherenvironments. As a result, the inner surface of the petroleum receptacleresists corrosion due to the high tin content of the upper layer, andthe outer surface of the petroleum receptacle resists corrosion from theoutside elements due to the tin and zinc in the upper layer and thecopper-zinc intermetallic layer below the upper layer. Consequently,this coating provides enhanced corrosion resistance for petroleumreceptacles.

[0077] In accordance with still yet another and/or alternative aspect ofthe present invention, the base metal coated with the metal alloycoating is coated with a sealant or protective layer. The protectivelayer can be chromate film, and/or an organic-inorganic composite film.In one embodiment of the invention, the protective coating is typicallyformulated to have a high compatibility with the metal alloy layer. Inanother and/or alternative embodiment of the invention, the protectivelayer is also typically formulated to cover imperfections in the metalalloy coating (e.g. pin holes, uncoated regions, etc), and/or toprovided additional corrosion resistance to the metal alloy coating. Instill another and/or alternative embodiment of the invention, theorganic-inorganic composite film includes acrylic, polyester and/orepoxy resins. In one aspect of this embodiment, the one or more resinsare used as a solvent type or a water soluble type and in the form ofthe organic-inorganic composite resin. In another and/or alternativeaspect of this embodiment, the organic-inorganic composite film includeschromium, silicon, phosphorus and/or manganese compounds these compoundscan improve adhesion, corrosion resistance and/or weldability coatedmetal alloy. In one non-limiting formulation, the chromium compound isadded in the form of chromic acid and/or a chromate. In another and/oralternative non-limiting formulation, the silicon compound is added assilicon oxides and/or silicon fluorides. In still another and/oralternative non-limiting formulation, the phosphorus compound is addedas organic or inorganic phosphoric acids and/or phosphates. In stillanother and/or alternative embodiment of the invention, the sealant orprotective coating includes an inorganic phosphate coating. Thephosphate coating be used separately or serve as a base for the laterapplication of a siccative organic coating composition such as paint,lacquer, varnish, primer, synthetic resin, enamel, and the like. Suchcoatings are disclosed in U.S. Pat. Nos. 3,454,483; 3,620,949;3,864,230; 4,007,102; 4,165,242; Re 27,896; and 5,603,818, which areincorporated herein by reference. In still another and/or alternativeembodiment of the invention, the protective coating is has a thicknessof about 1-150 microns, and typically about 1-50 microns. In still yetanother and/or alternative embodiment of the invention, the protectivelayer is at least partially dried by air drying and/or by heating lamps.

[0078] In accordance with yet another and/or alternative aspect of thepresent invention, the metal alloy and/or coated base metal basematerial can be formed on site without the metal alloy cracking and/orflaking off.

[0079] In accordance with still another and/or alternative aspect of thepresent invention, the metal alloy is formed into a corrosion-resistantstrip or sheet. In one embodiment of the invention, the metal alloystrip is formed by a roll forming process. In the roll forming process,a vat of molten metal alloy is provided. The molten alloy is thendirected through a series of rollers until the desired thickness of themetal alloy strip or sheet is obtained.

[0080] The primary object of the present invention is the provision of ametal alloy having corrosion-resistant properties.

[0081] Another and/or alternative object of the present invention is theprovision of a base metal coated with a metal alloy having corrosionresistant properties.

[0082] Still another and/or alternative object of the present inventionis the provision of a coated base metal which is bothcorrosion-resistant and environmentally-friendly.

[0083] Still yet another and/or alternative object of the presentinvention is the provision of a coated base metal having a sufficientcoating thickness to reduce or eliminate pinholes in the coating and/orwhich the shearing of the coating is inhibited when the coated basemetal is formed.

[0084] Another and/or alternative object of the present invention is theprovision of a coated base metal having a heat created intermetalliclayer formed between the base metal and the metal alloy coating.

[0085] Yet another and/or alternative object of the present invention isthe provision of a coated base metal at least partially coated by a hotdip process.

[0086] Still another and/or alternative object of the present inventionis the provision of at least partially coating a base metal by a platingprocess.

[0087] Yet still another and/or alternative object of the presentinvention is the provision of a base metal coated by a continuousprocess.

[0088] Still yet another and/or alternative object of the presentinvention is the provision of a coated base metal which is formed andsheared into various building and roofing components, automotivecomponents, marine products, household materials, and other formedmaterials that are subsequently assembled on site or in a formingfacility.

[0089] Another and/or alternative object of the present invention is theprovision of a coated base metal that is corrosion-resistant and whichcan be formed into complex shapes and/or ornamental designs.

[0090] Another and/or alternative object of the present invention is theprovision of a corrosion resistant metal alloy which includes a coloringagent to alter the color of the corrosion resistant metal alloy, acorrosion-resistance agent to improve the corrosion-resistance of thecorrosion resistant metal alloy, a mechanical agent to improve themechanical properties of the corrosion resistant metal alloy, a grainagent to positively affect grain refinement of the corrosion resistantmetal alloy, an oxidation agent to reduce oxidation of the moltencorrosion resistant metal alloy, an inhibiting agent to inhibit thecrystallization of the corrosion resistant metal alloy, and/or a bondingagent to improve the bonding characteristics of the corrosion resistantmetal alloy.

[0091] Still another and/or alternative object of the present inventionis the provision of a corrosion resistant metal alloy which includes amajority of tin.

[0092] Yet another and/or alternative object of the present invention isthe provision of a corrosion resistant metal alloy which includes amajority of tin and zinc.

[0093] Another and/or alternative object of the present invention is theprovision of applying an intermediate barrier metal layer to the surfaceof the base metal prior to applying the corrosion resistant metal alloycoating.

[0094] Still yet another and/or alternative object of the invention isthe provision of a coated base metal which is economical to produce.

[0095] Another and/or alternative object of the invention is theprovision of a coated base metal that can be soldered with conventionaltin-lead solders or no-lead solders.

[0096] Yet another and/or alternative object of the present invention isthe provision of pretreating the base metal prior to coating the basemetal with a corrosion resistant alloy to remove oxides and/or foreignmaterials from the surface of the base metal.

[0097] Another and/or alternative object of the present invention is theprovision of pickling the base metal to remove surface oxides on thebase metal prior to coating the base metal with a metal alloy.

[0098] Yet another and/or alternative object of the present invention isthe provision of chemically activating the base metal to remove surfaceoxides on the base metal prior to coating the base metal with a metal.

[0099] Still yet another and/or alternative object of the presentinvention is the provision of reducing the oxygen interaction with thebase metal prior to and/or during the coating process.

[0100] Another and/or alternative object of the present invention is theprovision of abrasively treating the surface of the base metal prior tocoating the base metal with a metal alloy.

[0101] Still yet another and/or alternative object of the presentinvention is the provision of a metal coating that is not highlyreflective.

[0102] Yet another and/or alternative object of the present invention isthe provision of a metal coating for a base metal which has a low leadcontent.

[0103] Still yet another and/or alternative object of the presentinvention is the provision of using spray jets to spray molten metalalloy onto the surface of the base metal to at least partially coat thesurface of the base metal.

[0104] Another and/or alternative object of the present invention is theprovision of coating a metal coating with a weathering agent toaccelerate the dulling of the surface of the metal alloy.

[0105] Still another and/or alternative object of the present inventionis the use of an air-knife process to at least partially control thethickness and quality of the metal alloy coating on the base metal.

[0106] Yet still another and/or alternative object of the presentinvention is the provision of cooling the metal alloy and/or a metalcoating to form fine and/or high density grains which produce a strongbonding, corrosive-resistant, and/or discolored coating.

[0107] Another and/or alternative object of the present invention is theprovision of at least partially subjecting the coated base metal to anoxidation solution to at least partially remove the metal alloy from thebase metal and to at least partially expose the heat createdintermetallic layer.

[0108] Still another and/or alternative object of the present inventionis the provision of subjecting the heat created intermetallic layer to apassivation solution to form a highly corrosion-resistant,non-reflective surface layer on the base metal.

[0109] Still yet another and/or alternative object of the presentinvention is the provision of a metal alloy coating which has superiorcorrosive characteristics permitting a thinner coating of the metalalloy to the base metal than that which is required for conventionalterne coatings with the high lead content.

[0110] Still yet another and/or alternative object of the presentinvention is the provision of using spray jets which at least partiallyspray metal alloy onto the coating rollers and/or base metal surface toreduce or eliminate non-coated surfaces on the base metal.

[0111] Another and/or alternative object of the present invention is theindirect heating of the melting pot without use of heating coils orheating rods.

[0112] Another and/or alternative object of the present invention is theprovision of a corrosion resistant metal alloy that can be coated on anumber of different base metal compositions.

[0113] Yet another and/or alternative object of the present invention isthe provision of a corrosion resistant metal alloy that can be coated ona base metal having a number of different shapes.

[0114] Still another and/or alternative object of the present inventionis the provision of providing a coated base metal which is formed by acontinuous, hot dip process wherein the base metal has a controlledresidence time when exposed to the molten metal alloy.

[0115] Still yet another and/or alternative object of the presentinvention is the provision of producing a highly corrosion-resistantcoated base material that has a desired zinc crystal size in the metalalloy.

[0116] A further and/or alternative object of the present invention isthe provision of producing a highly corrosion-resistant coated basematerial that includes a desired surface smoothness.

[0117] Still a further and/or alternative object of the presentinvention is the provision of producing a highly corrosion-resistantcoated base material that includes a protective coating on the surfaceof the metal alloy.

[0118] Yet a further and/or alternative object of the present inventionis the provision of producing a highly corrosion-resistant coated basematerial that includes an intermetallic layer that includes a majorityof copper and zinc.

[0119] Still yet a further and/or alternative object of the presentinvention is the provision of producing a highly corrosion-resistantcoated base material that is economical to make.

[0120] These and other objects and advantages will become apparent tothose skilled in the art upon the reading and following of thisdescription taken together with the accompanied drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0121] Reference may now be made to the drawings, which illustratevarious embodiments that the invention may take in physical form and incertain parts and arrangements of parts wherein;

[0122] FIGS. 1A-1B is a cross-sectional view of a hot dip processwherein a metal strip is coated with a corrosion resistant alloy byimmersing the metal strip in molten corrosion resistant metal alloy;

[0123]FIG. 2 is a cross-section view of additional and/or alternativeprocesses for handling the coated metal strip;

[0124]FIG. 3 is a cross-sectional view of the process of plating a metalstrip with a corrosion resistant metal alloy;

[0125]FIG. 4 illustrates a cross-sectional view of the process of flowheating the plated metal alloy;

[0126]FIG. 5 illustrates a cross-section view of an alternative processof cooling the hot-dip coated base metal in a cooling tank;

[0127]FIG. 6 illustrates a cross-sectional view of an alternativeprocess of using metal spray jets during the hot-dip coating process tocoat the metal strip;

[0128]FIG. 7 illustrates a cross-sectional view of an alternativeprocess of using an air-knife during the hot-dip coating process tocontrol the thickness of the coating on the metal strip;

[0129]FIG. 8 illustrates a cross-sectional view of an alternativeprocess of cooling the hot-dip metal alloy coated base metal by sprayjets;

[0130]FIG. 9 illustrates a cross-sectional view of an alternativeprocess of using abrasion treaters in conjunction with a low oxygenenvironment to pre-treat the base metal;

[0131]FIG. 10 is a frontal view of a camel-back guide;

[0132]FIG. 11 is a prospective view of a melting pot heated by gastorches;

[0133]FIG. 12 is a cross-sectional view of a coated metal strip having aheat-created intermetallic layer;

[0134]FIG. 13 illustrates a cross-sectional view of an alternativeprocess of using an oxidation process and rinse process to at leastpartially remove the metal alloy coating from the base metal to at leastpartially expose the heat created intermetallic layer;

[0135]FIG. 14 is a cross-sectional view of a coated metal strip having aheat-created intermetallic layer and passivated surface layer.

[0136]FIG. 15 illustrates a cross-sectional view of an alternativeprocess of coating a base metal by a hot dip process wherein a basemetal strip is unrolled and coated by immersing the metal strip in amolten pot of molten alloy and then subjecting the metal strip tocoating rollers and an air-knife process and then rolling the coatedmetal strip into a coil;

[0137]FIG. 16 is a plane view of a gasoline tank formed from the metalalloy or base metal coated with the metal alloy of the presentinvention;

[0138]FIG. 17 illustrates the joining of the first and second shellmembers of the gasoline tank at the peripheral edges;

[0139]FIG. 18 is a partial cross-sectional view of a gasoline tankillustrating a corrosion resistant coating on the metal shell after acoated base metal shell has been drawn;

[0140]FIG. 19 is a perspective view of a pair of adjacent roofing panelsformed from the metal alloy or base metal coated with the alloy of thepresent invention;

[0141]FIG. 20 is a cross-sectional view showing the initial assembly ofthe roofing panels of FIG. 19;

[0142]FIG. 21 is a cross-sectional view of the process of roll formingthe metal alloy of the present invention into a metal alloy strip;

[0143]FIG. 22 is a illustration of a copper base metal coated on bothsides with a tin and zinc metal alloy; and,

[0144]FIG. 23 is an enlarged portion of the copper base metal coatedwith a tin and zinc alloy that illustrates the heat createdintermetallic layer and the surface layer and a spectral analysis of theheat created intermetallic layer and the surface layer of the coatedcopper base metal.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0145] Referring now to the drawings, wherein the showings are for thepurpose of illustrating preferred embodiments of the invention only andnot for the purpose of limiting the same, reference is first had toFIGS. 1A-1B which illustrates one type of hot-dip process for coating ametal alloy on a base metal and forming a heat created intermetalliclayer between the metal alloy coating and the base metal. However, aswill be later discussed, the base metal can be alternatively coated by aprocess that does not form a heat created intermetallic layer betweenthe metal strip and metal alloy coating. The base metal and process usedto coat and/or pre-treat the base metal are illustrated in FIGS. 1-15.The base metal is in the form of a metal strip; however, other forms ofthe base metal can be used (i.e. metal plates, metal strip or metalplate formed into various shapes, various shaped metal objects) and becoated with a metal alloy in accordance with the present invention.

[0146] The metal alloy is a corrosion resistant alloy. When the metalalloy is coated onto the surface of a base metal, the metal alloyinhibits or prevent the base metal from corroding when exposed to theatmosphere. The metal alloy is highly corrosive resistant. The metalalloy is also typically abrasive resistant, pliable, weldable and/orenvironmentally friendly. The metal alloy binds with the base metal toform a durable protective coating which is not easily removable.

[0147] The amount of corrosion resistance protection provided by themetal alloy is of primary importance. The coating of the base metal withthe metal alloy functions to form a barrier to the atmosphere and/orsurrounding environment which inhibits or prevents the base metal fromcorroding. By coating the base metal with the metal alloy, the life ofthe base metal is extended for many years. The pliability of the metalalloy is also important when the coated base metal is to be formed. Formaterials such as, but not limited to, wall systems, roofing systems andpetroleum receptacles, the coated base metal is formed into variousshapes and is usually folded to form seams to bind together the coatedbase metal components. A metal coating on the base metal that forms arigid or brittle coating can crack and/or prevent the coated base metalcomponents from being properly shaped. The metal alloy of the presentinvention can be formulated to facilitate in the forming of a coatedbase metal. The metal alloy can also be formulated to be connectedtogether by solder or a weld.

[0148] Base metal, such as, but not limited to, carbon steel, stainlesssteel, copper, copper alloys, aluminum and aluminum alloys, oxidize whenexposed to the atmosphere and/or various types of chemicals or petroleumproducts. Over a period of time, the oxidized base metal can begin toweaken and disintegrate. The application of a corrosion resistant metalalloy onto the base metal acts as a barrier to the atmosphere,environment, and/or chemical or petroleum products to inhibit or preventthe oxidation of the base metal. By coating the base metal with thecorrosion resistant metal alloy, the life of the base metal can beextended for many years.

[0149] As illustrated in FIGS. 1A-1B, a base metal in the form of ametal strip 12 is provided from a large metal roll 10. Metal strip 12has a thickness of less than about 12700 microns, and typically about127-5080 microns; however, other metal strip thickness can be useddepending on the type of base metal and the use of the coated basemetal. Metal strip 12 is typically carbon steel, stainless steel,aluminum, aluminum alloy, copper or a copper alloy. Metal strip 12 isunwound from roll 10 at speeds which are generally less than about 400ft./min., typically about 1-150 feet, more typically about 70-250ft./min., and yet more typically about 50-115 ft/min. The metal stripspeed is ultimately selected so that the residence time of the metalstrip in contact with the molten metal alloy is sufficient to coat thedesired amount of strip to a desired thickness and to form a heatcreated intermetallic layer of a desired thickness.

[0150] After metal strip 12 is unrolled from metal roll 10, metal strip12 is optionally pretreated prior to being coated with the metal alloy.As illustrated in FIGS. 1A-1B, metal strip 12 is pretreated to cleanand/or remove surface oxides from the surface of the metal strip priorto the metal strip being coated with the corrosion resistant metalalloy. The type and number of pretreatment process for metal strip 12will depend on the surface condition of the metal strip. Typicallycarbon steel and stainless steel are subjected to one or morepretreatment process steps.

[0151] Metal strip 12 is illustrated in FIGS. 1A and 9 as being at leastpartially cleaned by an abrasion treater 14 after being unrolled frommetal roll 10. The abrasion treater includes brushes 16 that are drivenby motors. The brushes are placed in contact with metal strip 12 toremove foreign materials from the surface of metal strip 12, and/or toinitially etch and/or mechanically remove oxides from the surface ofmetal strip 12. Brushes 16 are typically biased against metal strip 12to cause friction between the brushes and metal strip 12, which frictionfacilitates in the cleaning and/or etching of the surface of metal strip12. Typically, brushes 16 are located on the top and bottom surface ofstrip 12. As can be appreciated, the brushes can be positioned to onlycontact a portion of the surface of the metal strip. Brushes 16 aretypically made of a material having a hardness equal to or greater thanmetal strip 12 so that the brushes will not quickly wear down whenremoving foreign materials and/or pre-etching the surface of metal strip12. In one non-limiting arrangement, the brushes are made of a metalmaterial such as, but not limited to, carbon steel wire brushes. Brushes16 typically rotate in a direction that is opposite of the direction ofthe moving metal strip. This opposite rotational direction of thebrushes causes increased abrasive contact with the surface of the metalstrip. The abrasion treatment of the metal strip surface can alsoinclude the use of absorbents, cleaners and/or solvents. Theseabsorbents, cleaners and/or solvents can be applied to part of or to thefull surface of metal strip 12 before, during and/or after metal strip12 is treated with brushes 16. The cleaners and/or solvents can include,but are not limited to, alkaline cleaners, acidic cleaners and/ororganic solvents. Typically a carbon steel strip or stainless steel stipis subjected to the abrasion treater, and/or absorbents, cleaners and/orsolvents.

[0152] After metal strip 12 passes through abrasion treater 14, if suchabrasion treater is used, metal strip 12 can be guided by strip guides13 to a low oxygen environment 20. As shown in FIGS. 1A and 9, stripguides 13 are positioned throughout the pretreatment and coatingprocesses to at least partially guide metal strip 12 through eachprocess. Low oxygen environment 20 is illustrated as being a low oxygengas environment that at least substantially surrounds the surface ofmetal strip 12 with low oxygen-containing gas 22. As can be appreciated,the low oxygen gas environment can be designed to only partially protectone or more surfaces of metal strip 12. The low oxygen-containing gasincludes, but are not limited to, nitrogen, hydrocarbons, hydrogen,noble gases and/or other non-oxygen containing gases. The lowoxygen-containing gas surrounds metal strip 12 and forms a barrieragainst the oxygen containing atmosphere thereby preventing orinhibiting oxide formation on the surface of metal strip 12. As can beappreciated, low oxygen environment 20 can include or in the alternativebe a low oxygen liquid environment. In a low oxygen liquid environment,the liquid can be sprayed on to one or more surfaces of the metal stripor the metal strip can be partially or fully immersed in the lowoxygen-containing liquid. Typically a carbon steel strip or stainlesssteel stip is subjected to the low oxygen gas environment.

[0153] Metal strip 12, after passing through low oxygen gas environment20, if such low oxygen environment is used, enters pickling tank 30which contains a pickling solution 32. The pickling solution isformulated to remove surface oxides from the metal strip surface, removedirt and other foreign materials from the metal strip surface and/oretch the surface of the metal strip. Pickling tank 30 is of sufficientlength and depth to allow for complete immersion of metal strip 12 inpickling solution 32 and to maintain the metal strip in contact with thepickling solution for a sufficient period of time. Typically, picklingtank 30 is at least about 25 feet in length. As can be appreciated, thepickling tank can be longer or shorter depending on the speed of themetal strip. Furthermore, the pickling tank can be designed so that onlya portion of the surface of metal strip 12 contacts the picklingsolution. The pickling solution typically contains one or more acids.The acids include organic and/or inorganic acids. Such acids include,but are not limited to, perchloric acid, hydrofluoric acid, sulfuricacid, nitric acid, hydrochloric acid, phosphoric acid, and/or isobromicacid. Typically, pickling solution 32 includes hydrochloric acid.Generally, the pickling solution contains at least about 5% by volumehydrochloric acid. For metal strip having extensive surface oxidesand/or difficult to remove surface oxides such as, but not limited to,stainless steel strip, an aggressive pickling solution can be used. Onetype of aggressive pickling solution is a dual acid solution ofhydrochloric acid and nitric acid. Formulations of thehydrochloric-nitric acid include a) about 1-30% by volume hydrochloricacid and about 0.1-15% by volume nitric acid, b) about 5-25% by volumehydrochloric acid and 1-15% by volume nitric acid, and c) about 10%hydrochloric acid and 3% nitric acid. Pickling solution 32 is maintainedat a temperature to obtain the desired activity of the picklingsolution. Typically, pickling solution 32 is maintained at a temperatureof at least about 26° C., generally about 48-60° C., and typically about53-56° C. Pickling tank 30 is shown as containing one or more agitators34; however, such agitators are not required. Agitator 34 is designed toagitate pickling solution 32 to maintain a uniform solutionconcentration, maintain a uniform solution temperature and/or break upgas pockets which form on the surface of metal strip 12. Agitator 34typically includes an abrasive material which can both agitate picklingsolution 32 and remove of oxides from metal strip 12 when in contactwith the surface of the metal strip. Agitator 34 is typically made of amaterial which does not react with pickling solution 32 and resistsundue wear when in contact with the metal strip surface. Metal strip 12is typically not exposed to the pickling solution for more than about 10minutes so as to avoid pitting of the metal strip surface; however,longer pickling times can be used depending on the type of picklingsolution, concentration and temperature of the pickling solution, typeof metal strip, and/or condition of metal strip surface. Typically, thepickling time is less than about ten minutes, more typically less thanabout two minutes, still more typically less than about one minute, andyet more typically about 10-20 seconds. A pickling solution vent 36 istypically placed above pickling tank 30 to collect and remove acid fumesand other gasses escaping pickling tank 30. Typically a carbon steelstrip or stainless steel stip is subjected to a pickling solution.

[0154] As illustrated in FIG. 1A, metal strip 12 enters another lowoxygen environment 20 after exiting pickling tank 30. After metal strip12 exits pickling tank 30, the surface of metal strip 12 is essentiallyabsent surface oxides and other foreign materials and is highlysusceptible to oxidation with oxygen and other gases in the atmosphere.Low oxygen environment 20 shields the surface of metal strip 12 fromoxygen and other oxidizing gases and/or liquids thereby inhibiting oxideformation on the metal strip surface. Low oxygen environment 20 is a lowoxygen-containing gas environment similar to the low oxygen environmentused after the abrasion treatment process; however, a lowoxygen-containing liquid environment could be used in conjunction withor as an alternative to the low oxygen-containing gas environment.Typically a carbon steel strip or stainless steel stip is subjected tothe low oxygen gas environment.

[0155] After metal strip 12 exits low oxygen environment 20, metal strip12 enters rinse tank 40 which contains a rinse solution 42. Rinse tank40 is designed to remove any remaining pickling solution 32 on thesurface of metal strip 12 and/or inhibit the formation of oxides on themetal strip surface. One type of rinse solution includes water that isdeoxygenated by heating the water above about 38-43° C. (100-110° F.).As can be appreciated, other rinse liquids can be used. Rinse solution42 can remove small amounts of oxides that remain on the surface ofmetal strip 12. The rinse solution typically is slightly acidic due tothe acidic pickling solution that is removed from the metal stripsurface. As can be appreciated, the rinse solution can be alternativelyor additionally acidified by the intentional addition of acid to therinse solution. The slightly acidic rinse solution 42 removes smallamounts of oxides on the surface of metal strip 12. Rinse tank 40 is ofsufficient length and depth to facilitate complete immersion of metalstrip 12 in rinse solution 42 and to maintain the metal strip in contactwith the rinse solution for a sufficient period of time. Typically,rinse tank 40 is at least about 20 feet in length. Metal strip 12 istypically not resident in the rinse tank for more than about 10 minutes;however, longer rinsing times can be used. As can be appreciated, therinse tank can be longer or shorter depending on the speed of the metalstrip. Furthermore, the rinse tank can be designed so that only aportion of the surface of metal strip 12 contacts the rinse solution.The rinse tank typically includes one or more agitators, not shown. Theagitators are designed to agitate rinse solution 42 to maintain auniform solution concentration, maintain a uniform solution temperature,and/or break up gas pockets which form on the surface of metal strip 12.The agitators typically include an abrasive material which can bothagitate the rinse solution and remove remaining oxides on the surface ofmetal strip 12 when in contact with the surface of the metal strip. Theagitators are typically made of a material which does not react withrinse solution 42 and resists undue wear when in contact with the metalstrip surface. As can be appreciated, the metal strip can bealternatively or additionally rinsed by spraying a rinse fluid onto aportion or the full surface of metal strip 12. Typically a carbon steelstrip or stainless steel stip is subjected to the rinse solution afterbeing subjected to a pickling solution.

[0156] Referring now to FIG. 1B, metal strip 12 enters low oxygenenvironment 50 after exiting rinse tank 40. Low oxygen environment 50 isa low oxygen-containing liquid environment which includes spray jets 52.Spray jets 52 are located on each side of metal strip 12 so as to directthe low oxygen-containing liquid onto both sides of metal strip 12. Ascan be appreciated, the spray jets can be positioned about metal strip12 so that only a portion of the strip surface is subjected to the lowoxygen-containing liquid. The low oxygen-containing liquid 56 inhibitsoxide formation of the metal strip surface. Spray jets 52 also removeany remaining pickling solution 32 or other acid on the surface of metalstrip 12. Low oxygen-containing liquid 56 is typically heated waterhaving a temperature of at least about 38-43° C. (100-110° F.). As canbe appreciated, other low oxygen-containing liquids can be used.Furthermore, it can be appreciated that low oxygen environment 50 caninclude or in the alternative be a low oxygen-containing gasenvironment.

[0157] Metal strip 12, upon leaving low oxygen liquid environment 50,enters chemical activation tank 60 which includes a chemical activatingsolution or deoxidizing solution 62. The chemical activation tank is ofsufficient length and depth to facilitate complete immersion of metalstrip 12 in deoxidizing solution 62 and to maintain the metal strip incontact with the deoxidizing solution for a sufficient period of time.Typically, chemical activation tank is at least about 25 feet in length.As can be appreciated, the chemical activation tank can be longer orshorter depending on the speed of the metal strip. Furthermore, thechemical activation tank can be designed so that only a portion of thesurface of metal strip 12 contacts the deoxidizing solution. Thechemical activation tank typically includes one or more agitators, notshown. The agitators are designed to agitate deoxidizing solution 62 tomaintain a uniform solution concentration, maintain a uniform solutiontemperature and/or break up gas pockets which form on the surface ofmetal strip 12. The agitators typically include an abrasive materialwhich can agitate the deoxidizing solution and/or remove remainingoxides on the surface of metal strip 12 when in contact with the surfaceof the metal strip. The agitators are typically made of a material whichdoes not react with deoxidation solution and resists undue wear when incontact with the metal strip surface. The metal strip is generallysubjected to the deoxidizing solution for less than about 10 minutes,and typically less than about one minute; however, longer times can beused. Deoxidizing solution 62 is formulated to remove remaining oxideson the surface of metal strip 12 and/or act as a protective coating toinhibit oxide formation on the surface of metal strip 12. Thetemperature of the deoxidizing solution is maintained at a temperatureto achieve sufficient activity of the deoxidizing solution. Typically,the temperature of the deoxidizing solution is maintained at least about15° C., typically about 15-33° C., and more typically about 26-33° C.The deoxidizing solution typically includes zinc chloride; however,other chemical compounds can be used. Small amounts of an acid can beadd to the deoxidizing solution to further enhance oxide removal fromthe metal strip surface. One specific deoxidizing solution formulationincludes at least about 1% by volume zinc chloride. Another specificdeoxidizing solution formulation includes about 5-50% by volume zincchloride. Yet another specific deoxidizing solution formulation includesabout 5-50% by volume zinc chloride and about 0.5-15% by volumehydrochloric acid.

[0158] After metal strip 12 exits chemical activation tank 60, metalstrip 12 enter the final pretreatment step of immersion in a fluxsolution 74 contained in flux box 72. As can be appreciated, metal strip12 can be exposed to a low oxygen environment, not shown, prior toentering flux solution 74 to inhibit or prevent oxide formation on themetal strip surface after the metal strip exits chemical activation tank60. As also can be appreciated, flux box 72 can be designed so that onlya portion of metal strip 12 is exposed to flux solution 74. Flux box 72is located in melting pot 70. The flux solution in flux box 72 has aspecific gravity that is less than or equal to the specific gravity ofmolten corrosion resistant metal alloy 76 so that flux solution 74 atleast partially floats on the surface of the molten corrosion resistantmetal alloy. Flux solution 74 typically includes zinc chloride andammonium chloride; however, other compounds can be used. Specificnon-limiting formulations of flux solution 74 include a) about 20-75% byvolume zinc chloride and 1-40% by volume ammonium chloride, b) about20-75% by volume zinc chloride and 1-20% by volume ammonium chloride, c)about 30-60 weight percent zinc chloride and up to about 40 weightpercent ammonium chloride, d) about 30-60 weight percent zinc chlorideand about 5-40 weight percent ammonium chloride, and e) about 50 weightpercent zinc chloride and about 8 weight percent ammonium chloride. Ascan be appreciated, other concentrations of these two components can beused. Flux solution 74 is the final pre-treating process of metal strip12 for removal of remaining oxides on the surface of metal strip 12prior to being coated with metal alloy 76. Flux box 74 also acts as abarrier to oxygen and prevents or inhibits oxides from forming on thesurface of the metal strip and on the surface of the molten metal alloycovered by the flux solution.

[0159] The one or more pretreatment processes described above may or maynot be used for a particular type of metal strip. For example, carbonsteel strip may only be pickled and rinsed prior to being coated with ametal alloy. Stainless steel strip may be subjected to all of thepretreatment process set forth above prior to being coated with a metalalloy. Copper strip may only be rinsed prior to being coated with ametal alloy. As set forth above, the use of one or more of thepretreatment processes as set forth above is generally dependent on thetype of metal strip, the condition the metal strip is in after beingunrolled from metal roll 10, and/or type of pretreatment processesselected from the metal strip (e.g. if pickling is selected, then arinse process is also used).

[0160] An additional or alternative pretreatment process is the coatingof metal strip 12 with an intermediate barrier metal layer prior tocoating the metal strip with the corrosion resistant metal alloy. Thecoating of the metal strip with an intermediate barrier metal layer canconstitute the only pretreatment process for the metal strip, or themetal strip can be pretreated with one or more other pretreatmentprocess before and/or after the metal strip is coated with anintermediate barrier metal layer. The intermediate barrier metal layeris typically a thin layer of metal such as, but not limited to, tin,nickel, copper, chromium, aluminum, cobalt, molybdenum, Sn—Ni, Fe—Ni,and/or zinc. The thickness of the layer is generally less than about 500microns and typically less than about 100 microns. The intermediatebarrier metal layer can be applied by an electroplating process asillustrated in FIG. 3, an electroplating process and subsequent heatingof the plated layer, immersion in molten metal, metal spraying, coatingrollers, and the like. The process for plating the intermediate barriermetal layer onto the surface of metal strip 12 is typically by aconventional continuous plating process. The applied intermediatebarrier metal layer typically forms a strong bond with the metal strip,whether or not the strip surface has been pretreated with one or moreother pretreatment processes. The bonding of the intermediate barriermetal layer to the strip is enhanced by heating the intermediate barriermetal layer and the forming a heat created intermetallic layer betweenthe metal strip and the intermediate barrier metal layer. When theintermediate barrier metal layer is plated and then flow heated, thethickness of the intermediate barrier metal layer is typically at leastabout 2 microns so that a sufficiently thick intermediate barrier metallayer exists for proper flow heating. The selection of metal of theintermediate barrier metal layer can advantageously change thecomposition of the heat created intermetallic layer thereby improvingcorrosion resistance, improving metal alloy bonding, improve metal alloypliability, and/or inhibiting the formation of a thick zinc layer in theintermetallic layer when zinc is included in the metal alloy. In onespecific non-limiting embodiment of the invention, a non-copper metalstrip or non-copper alloy metal strip is coated with copper or copperalloy prior to applying the metal alloy. The copper or copper alloy canbe applied by plating, cladding or other manner of bonding the copper orcopper alloy to the metal strip. Generally the thickness of the copperor copper alloy is about 2-100 microns, and typically about 2-50microns.

[0161] Another additional or alternative pretreatment process is thepreheating of the metal strip prior to coating the metal strip with thecorrosion resistant metal alloy. Metal strip that has a thickness ofless than about 762 microns is typically not pre-heated. Thicker metalstrip can be preheated to assist in the formation of the heat createdintermetallic layer. A thin metal strip generally does not need to bepreheated since the surface of the thin strip quickly heats to thetemperature of the molten metal alloy. As the surface of the metal stripapproaches the temperature of the molten metal alloy, an intermetalliclayer begins to form between the surface of the metal strip and themetal alloy coating. Metal strip having a thickness of up to about 762microns is classified as thin metal strip. However, thin metal strip canbe preheated and such preheated strip can result in the quickerformation of an intermetallic layer. Metal strip having a thickness overabout 762 microns is classified as a thick metal strip. Thick metalstrip is typically preheated prior to coating with the metal alloy. Thesurface of a thick metal strip takes a longer time to approach thetemperature of the molten metal alloy due to the larger heat sink of thethicker metal strip. Preheating the thick metal strip facilitates in thesurface of the metal strip reaching or approaching the moltentemperature of the metal alloy during the coating process so that adesired heat created intermetallic layer is formed. Metal strip 12 canbe preheated in any number of ways, such as but not limited to,convection or induction heating, flames, lasers, and the like. When aheat created intermetallic layer is not to be formed, the meal strip istypically not pre-heated.

[0162] Although FIGS. 1A-1B illustrate metal strip 12 being pretreatedby the pretreatment processes of abrasion, pickling and rinsing,chemical activation, exposure to low oxygen environment, and the fluxsolution, the use of all these pretreatment process on all types ofmetal strip is not always required. When the metal strip has a cleansurface and/or little or no oxide formation on the metal strip surface,the pretreatment process can be eliminated or only a select number ofpretreatment processes can be used prior to coating the metal strip withthe corrosion resistant metal alloy.

[0163] Referring to FIG. 1B, metal strip 12, after exiting flux box 72,enters molten corrosion resistant metal alloy 76. Melting pot 70 istypically heated by heating jets, coils, rods, heat exchangers, etc. Inone non-limiting arrangement, melting pot 70 is heated by four heatingjets 71 directed at the outside sides of melting pot 70 as shown in FIG.11. The heating jets are typically gas jets. Melting pot 70 ismaintained at a temperature of at least several degrees Celsius abovethe melting point of corrosion resistant metal alloy 76 to inhibit orprevent solidification of metal alloy 76 as metal strip 12 enters intoand passes through melting pot 70. Tin melts at about 232° C. (450° F.).Zinc melts at about 419.6° C. (787° F.). When additives and/orimpurities are included in the tin alloy or tin and zinc alloy, themelting point of metal alloy 76 will be altered. The composition and/orthickness of melting pot 70 is selected to accommodate the various metalalloy melting temperatures. The temperature of the molten metal alloycan be up to or more than 38° C. cooler at the top of the melting potthan at the bottom of the melting pot. Typically, the tin alloy or tinand zinc alloy is maintained at least about 2-30° C. above the meltingpoint of the metal alloy at the top of the melting pot. The temperatureof the metal alloy in the melting pot is selected to accommodate theinclusion of additives and/or impurities in metal alloy 76. Generally,the temperature of the molten metal alloy in the melting pot is about231-538° C. For high melting point metal alloys, additional heating jetsor other additional heating devices can be used to heat the metal alloyin the melting pot to the desired temperature.

[0164] The molten metal alloy in the melting pot is generally formed byadding ingots of tin for a tin alloy coating and ingots of tin andingots of zinc for a tin and zinc alloy coating into the melting potwherein the ingots are melted and mixed. The ingots may contain someadditional elements which function as additives or impurities in the tinalloy or tin and zinc alloy. The amount of impurities in the metal alloyare generally controlled so as to reduce the adverse affects of suchimpurities.

[0165] As shown in FIG. 1B, melting pot 70 is divided into two chambersby barrier 80. Barrier 80 is designed to inhibit or prevent protectivematerial 78, such as palm oil, from spreading over the complete topsurface of molten corrosion resistant metal alloy 76 in melting pot 70.As can be appreciated, barrier 80 can be eliminated. When the protectivematerial is palm oil, the melting point of the metal alloy should bebelow the 343° C. so as to not degrade the palm oil. For metal alloyshaving higher melting point temperatures, special oils, fluxes, or othermaterials and/or special cooling procedures are employed when aprotective material is used. Protective material 78 has a specificgravity which enables the protective material to at least partiallyfloat on the surface of molten alloy 76. The protective materialinhibits or prevents the surface of molten metal alloy from solidifyingby insulating the surface from the atmosphere, inhibits or prevents thesurface of molten metal alloy from oxidizing, and/or aids in theproperly distribution the metal alloy on the surface of metal strip 12upon exiting the molten metal alloy.

[0166] Melting pot 70 is generally about 10-100 ft. in length so as toprovide an adequate residence time for the metal strip in the moltenmetal alloy as the metal strip moves through the molten metal alloy 76in the melting pot. Longer melting pot lengths can be employed for fastmoving metal strip. The residence time of the metal strip in the moltenmetal alloy is sufficiently long enough to form the desired thickness ofheat created intermetallic layer 140 and the desired thickness of themetal alloy. The residence time of metal strip 12 in melting pot 70 isgenerally at least about 5 seconds and less than about 10 minutes,typically less than about 2-10 minutes, more typically less than aboutone minute, still more typically about 5-30 seconds, and even moretypically about 10-30 seconds. When the metal strip is coated with themetal alloy by a continuous immersion process, the metal strip istypically moved through the molten tin alloy in the melting pot in acurvilinear path; however, other paths can be used. When the metal stripuses a curvilinear path, the metal strip requires fewer, if any, guiderolls (driving rollers), especially when the metal strip is made of amore malleable material such as, but not limited to, aluminum or copper.The curvilinear path of the metal strip allows the metal strip to atleast partially dictate its path in the molten metal alloy. The coatingthickness of the metal alloy onto the metal strip is generally afunction of the time the metal strip is resident or immersed in themolten tin alloy. The coating thickness typically increases the longerthe metal strip is maintained in the molten metal alloy. In a continuousimmersion coating process, the resident time of the surfaces of themetal strip in the molten metal alloy is substantially the same. Theuniformity of residence time in the molten metal alloy results in a moreuniform coating thicknesses on the surface of the metal strip andsubstantially uniform growth of the heat created intermetallic layer.The metal strip is typically maintained at a constant speed through themolten metal alloy to create a more smooth coated surface. As the metalstrip passes through the molten metal alloy at a substantially constantspeed, the molten metal alloy about the metal strip adheres to themoving metal strip and shears a portion of the coating from the movingmetal strip. This shearing effect results from the viscosity of themolten metal alloy and the speed at which the metal strip is movingthrough the molten metal alloy. For a given speed and molten metal alloyviscosity, a constant shearing effect is applied to the surface of themoving metal strip thereby smoothing the coated surface and facilitatingin the formation of a substantially constant coating thickness. By usinga continuous coating process to coat the metal strip with a metal alloy,a uniform of coating (weight and thickness) is obtained, havingexcellent surface appearance, smoothness, texture control and asubstantially uniform heat created intermetallic layer.

[0167] During the coating of the metal strip with molten metal alloy, aheat created intermetallic layer 140 formed between the metal alloycoating layer 142 and metal strip 12 as shown in FIG. 12. The heatcreated intermetallic layer includes elements of the corrosion resistantmetal alloy molecularly intertwined with elements on the surface ofmetal strip 12. This molecular intertwining occurs when the temperatureof the surface of the metal strip approaches the temperature of themolten corrosion resistant metal alloy. The migration of the corrosionresistant metal atoms into the surface layer of strip 12 results in theformation of heat created intermetallic layer 140. A copper strip coatedwith a tin and zinc alloy or another metal that was coated with copperan then coated with a tin and zinc alloy would form an intermetalliclayer that includes at least copper and zinc. Intermetallic layer 140can include a number of elements such as, but is not limited to,antimony, aluminum, arsenic, bismuth, cadmium, chromium, copper,hydrogen, iron, lead, magnesium, manganese, nickel, nitrogen, oxygen,silicon, silver, sulfur, tellurium, tin, titanium, zinc and/or smallamounts of other elements or compounds depending on the composition ofthe metal strip, the corrosion resistant alloy, and the intermediatebarrier metal layer (if used). Heat created intermetallic layer 140 canbe thought of as a transition layer between metal strip 12 and corrosionresistant alloy coating 142. Heat created intermetallic layer 140 isbelieved to be at least partially responsible for the strong bond formedbetween corrosion resistant metal alloy layer 142 and metal strip 12.The heat created intermetallic layer also typically functions as acorrosion-resistant layer. Typically, the thickness of the heat createdintermetallic layer is at least about 0.1 micron, and typically about1-50 microns; however, thicker heat created intermetallic layers can beformed. The time needed to form the heat created intermetallic layer istypically less than about three minutes and generally less than aboutone minute; however, longer times can be used.

[0168] As shown in FIGS. 1B and 6, metal strip 12 passes between atleast one set of coating rollers 82 upon exiting the molten metal alloyin melting pot 70. As best shown in FIG. 6, the coating rollers arepartially immersed in protective material 78. As can be appreciated, thecoating rollers can be completely immersed in the protective material orpositioned above the protective material. Coating rollers 82 are spacedapart a sufficient distance so that the coated metal strip can passbetween the coating rollers. The coating rollers 82 are designed tomaintain a desired coating thickness of the metal alloy on the metalstrip, remove excess metal alloy 76 from the metal strip, and/or coatany non-coated regions on the surface of the metal strip. The coatingthickness of the metal alloy is generally selected to ensure thatlittle, if any, uncoated regions exist on the surface of the metalstrip. Typically, the thickness of the metal alloy on the surface ofmetal strip 12 is at least about 1 micron, and generally about 7 to 2550microns. The coating thickness is typically selected to ensure thecoated metal alloy has few, if any, pin holes, and/or does not shearwhen formed into various products. The thickness of the metal alloy istypically selected depending on the environment in which the coatedmetal strip is to be used. A metal alloy coating thickness of about25-51 microns generally forms a coating that has few pin holes, providesgreater elongation characteristics of the coated metal strip, and/orsignificantly reduces the corrosion of the metal strip in virtually alltypes of environments. Metal alloy coating thicknesses greater thanabout 51 microns are typically used in harsh environments to provideadded corrosion protection.

[0169] Referring again to FIGS. 1B and 6, a metal spray process is shownwherein metal coating jets or spray jets 84 inject molten metal alloy 76on the surface of coating rollers 82. As can be appreciated, metalcoating jets 84 can be used to exclusively coat the metal strip, or beused in conjunction with a melting pot, coating rollers and/or othercoating process to apply metal alloy onto the surface of metal strip 12.As shown in FIG. 6, molten metal alloy is spray jetted from metalcoating jets 84 onto coating rollers 82 is then pressed against metalstrip 12 by coating rollers 82 as the metal strip 12 moves between thecoating rollers thereby filling in most, if not all, uncoated surfaceareas on metal strip 12 which were not coated as the metal strip passedthrough the molten alloy in melting pot 70. The motel metal alloy thatis supplied to the metal spray jets is at least partially taken from themelting pot 70 and pumped by pump P through a pipe and to the metalspray jets. As can be appreciated, the metal spray process and/or thecoating rollers can be used independently of the melting pot and/or bethe sole coating process used to coat the metal alloy onto the metalstrip.

[0170] Referring now to FIG. 7, an air-knife 100 can be used to direct ahigh velocity gas toward metal alloy coating 76 on metal strip 12 as themetal strip exits melting pot 70. The air knife includes at least oneblast nozzle 104 that direct a high velocity gas onto the surface of themetal alloy on the metal strip. Typically, air knife includes at leasttwo blast nozzles 104 which are mutually opposed from each other and aredisposed over melting pot 70. The blast nozzles direct high velocity gas105 toward metal strip 12 and toward the surface of melting pot 70 asthe metal strip moves by or between the blast nozzles. Generally, theblast nozzles are adjustable so as to direct the high velocity gas atvarious angles on to the surface of the metal strip. The high velocitygas removes surplus molten metal alloy coating 102 from the metal strip,smears the molten alloy on metal strip 12 to cover uncoated regions onthe metal strip, reduces the thickness of the metal alloy coating on themetal strip, reduces lumps or ribs in the metal alloy coating, cools themetal alloy coating, and/or hardens the metal alloy coating. The highvelocity gas is typically an inert gas so as not to oxidize the moltenmetal alloy. Use of an inert gas also reduces dross formation on themetal alloy coating and/or acts as a protective barrier to theatmosphere which causes viscous oxides to form on the surface of themolten metal alloy in melting pot 70. When inert gas is used, the use ofa protective material on the surface of the melting pot can beeliminated. Generally, the inert gas is, but is not limited to, nitrogenor an inert gas that is heavier than air (i.e. has a higher density thanair). The blast nozzles are typically enclosed in a box shaped sleevewhich accumulates at least a portion of the gas after the gas isdirected toward the metal strip. The accumulated gas can then berecirculated back through the blast nozzles. When an air-knife is usedto control the thickness and/or quality of the metal alloy coating, theair-knife is generally used as a substitute for or used in conjunctionwith coating rollers 82. As can be appreciated, the air-knife processcan be used after the metal strip is coated by one or more coatingrollers and/or by a metal spray jet.

[0171] Referring now to FIG. 3, an alternative process for coating metalstrip 12 with a corrosion resistant metal alloy is illustrated. FIG. 3was previously referred to as illustrating a plating process forapplying a plated intermediate metal barrier. FIG. 3 is now referencedas also illustrating the coating of a metal strip with a corrosionresistant metal alloy by an electroplating process. This coating processfor the metal alloy is a non-hot-dip process in that a heat createdintermetallic layer is not formed between the metal strip and metalalloy coating. Metal strip 12 is directed into electrolytic tank 44 andsubmerged in electrolyte 46. Metal strip 12 can be directed intoelectrolytic tank 44 immediately after being unrolled from metal roll10; after being pretreated by one or more pretreatment processes; and/orafter being coated with metal alloy by immersion, spray metal coating,and/or roller coating. As metal strip 12 passes through electrolytictank 44, an electrical current is directed into electrolyte 46 byelectrodes 48. The current through electrodes 48 is supplied by powersource 49. The plating of the metal alloy onto the surface of the metalstrip is typically effectuated by conventional electroplating processes.The metal alloy can be plated onto the surface of metal strip 12 by oneor more plating operations. After the metal strip is plated with themetal alloy, the metal strip is moved out of electrolytic tank 44. Thethickness of the plated corrosion resistant alloy is generally at leastabout 1 micron, and typically less than about 200 microns. Coatingthickness of 2-77 microns, and 10-77 microns are typical coatingthicknesses. After the metal strip exits electrolytic tank 44, thecoated metal strip can be further treated by rinsing, heating, coatingwith a metal alloy by a hot-dip process, and/or one or more posttreatment processes.

[0172] When a heat created intermetallic layer is to be formed betweenthe metal strip and the plated metal alloy coating, the plated metalalloy coating is heated. FIG. 4 illustrates one heating process used toform a heat created intermetallic layer between the metal strip and theplated metal alloy coating. Coated metal strip is continuously movedbetween two heaters 58. Heaters 58 cause the plated corrosion resistantmetal alloy to soften and/or become molten. This process of heating theplated metal alloy is referred to as flow heating and constitutesanother type of hot-dip process. During the flow heating process, a heatcreated intermetallic layer is formed between the metal strip and metalalloy coating. The plated metal alloy is subjected to heat for asufficient time period to form a heat created intermetallic layer havinga desired thickness. As can be appreciated, the heating process canoccur is a single or a multiple stage process. Furthermore, the heatingprocess can be designed to heat a part of or the complete coated regionon the metal strip. After the metal strip is flow heated, the metalalloy coating can be further modified by a process such as, but notlimited to, controlling the coating thicknesses by an air-knife processand/or a coating roller process, and/or coating additional layers ofmetal alloy by additional coating process such as, but not limited to, aplating process, a metal spray process, a coating roller process, and/oran immersion process.

[0173] After metal strip 12 is coated with a corrosion resistant alloy,the coated metal strip is cooled and/or rinsed. A coated metal stripthat is plated as it moves through an electrolyte solution is typicallyrinsed off to remove electrolyte solution remaining on the surface ofthe coated metal strip. A coated metal strip that is coated by a hot-dipprocess is typically cooled to reduce the temperature and/or harden themetal alloy coating. Referring to FIGS. 1B, 8 and 10, the coated metalstrip can be cooled by applying a cooling fluid 93 on the coated metalstrip by at least one spray jet 92. Typically, the cooling fluid is, butnot limited to, water maintained at about ambient temperature. As can beappreciated, multiple temperature cooling fluids can be applied to thecoated metal strip. For example, the coated metal strip can be firstcooled by steam and then by water near ambient temperature. The velocityof the cooling fluid can be varied to obtain the desired cooling rateand/or rinsing effect of the corrosion resistant metal alloy. Asillustrated in FIGS. 1B and 10, metal strip 12 is guided by camel-backguides 90 during the cooling process. Camel-back guide 90 is designedsuch that it has two receding edges 91 formed by conical surfaces whichcontact only the edges of metal strip 12 so as to minimize the removalof the metal alloy coating from metal strip 12. Alternatively or inaddition to the spray cooling process, the coated metal strip can becooled in a cooling tank 94 as illustrated in FIG. 5. The coated metalstrip is partially or fully immersed in the cooling fluid 96 to cooland/or rinse the coated metal strip. Typically, the cooling fluid is,but not limited to, water maintained at about ambient temperature. Thecooling fluid is also typically agitated to increase the rate of coolingof the metal alloy coating, and/or maintain a relatively uniform coolingfluid temperature. The temperature of the cooling water is typicallymaintained at proper cooling temperatures by recycling the water throughheat exchangers and/or replenishing the cooling fluid. The cooling watermay not be deoxygenated prior to cooling the coated metal strip coatingso as to slightly discolor the metal alloy coating and/or reduce thereflectiveness of the metal alloy coating. Immersion of the coated metalstrip in cooling fluid 96 generally results in a faster cooling ratethan cooling by spray jets 92. Rapid cooling of the corrosion resistantmetal alloy generally produces a metal alloy coating having fine grainsize with increased grain density. Typically, the metal alloy is cooledat a rate such that there are no more than about 40 zinc crystals in themetal alloy have a maximum dimension of over about 400 μm within a 0.25mm² region of the metal alloy. In addition, cooling of the metal alloycoating in water results in some oxidation of the metal alloy coatingsurface which can result in a less-reflective surface, if such a surfaceis desired. The cooling period for cooling coated metal strip 12 bycooling jets 92 or by immersion in cooling tank 94 is generally lessthan about 10 minutes, typically less than about 5 minutes, moretypically less than about 2 minutes, and even more typically about 10-30seconds.

[0174] After the coated metal strip is cooled, the coated metal stripmay be rolled into a metal roll, partially or totally formed intovarious shapes (i.e. roofing materials, building materials, householdparts, automotive parts, etc.), cut into sheets, or processed by a postcoating process (e.g oxidation of the coating to partially or fullyexpose the heat created intermetallic layer, passifying the heat createdintermetallic layer, etc.).

[0175] As illustrated in FIG. 15, the metal strip is unrolled andimmediately directed into a molten bath of metal alloy without any priorpretreatment processes. Copper metal strip is typically unrolled andimmediately coated with a molten metal alloy as illustrated in FIG. 15.Upon exiting the molten metal bath, the metal strip passes betweencoating rollers and is then subjected to an air-knife process to controlthe coating thickness and reduce the uncoated regions on the metal stripsurface. The air-knife also cools and hardens the metal alloy coating sothat the coated metal strip can be immediately rolled into a metal roll150.

[0176] As illustrated in FIG. 2, the coated metal strip can be furtherprocessed prior to being rolled into a metal roll 150 or cut in tosheets 130. This further processing includes, but is not limited to,leveling, shearing, oxidizing the coated corrosion resistant alloy,passifying the metal alloy and/or heat created intermetallic layer,applying weathering agents, applying paints, sealants etc. As shown inFIG. 2, the coated metal strip is subjected to a leveler 100. Leveler100 includes several rollers 102 which produce a uniform and smoothcorrosion resistant alloy coating 142 on metal strip 12. Typically thesurface coarseness Ra of the metal alloy after passing through theleveler is less than about 5 μm. After metal strip 12 exits leveler 100,metal strip 12 is illustrated as being cut into sheets 130 by shear 111.The coated metal sheets or strip can be further processed by applying apaint, sealant or weathering agent on the surface of the coated metalsheets or strip. The paint, sealant or weathering agent 112 can beapplied to a portion or the full surface of the coated metal alloy. Thepaint, sealant or weathering agent can be applied by coaters 114 and/orby sprayers 116. A reservoir 110 holds the paint, sealant or weatheringagent for coaters 114 and/or sprayers 116. After the paint, sealant orweathering agent is applied, it can be dried by heat lamp 120 and/or bya dryer 122.

[0177] When a weathering agent is applied to the coated metal strip, theweathering agent is used to accelerate the patina formation on the metalalloy coating. This process is generally used to discolor the metalalloy and/or reduce the reflectiveness of the metal alloy. The naturalweathering of the metal alloy can take, in some instances, over tenyears to weather to the desired degree. The weathering agent isformulated to reduce the time period of weathering. In one non-limitingformulation, the weathering agent is typically a petroleum basedproduct. Generally, the petroleum based weathering agent is an asphaltbased paint containing a suspension of free carbon and a thinner. Whenthis formulation is used, a thin film or coating of weathering agent isapplied to the surface of the metal alloy and the ultraviolet light fromthe atmosphere facilitates in accelerating the weathering of the metalalloy. Generally, the thin layer of weathering agent is asemi-transparent or translucent coating and at least partially allowsthe metal alloy to be exposed to oxygen, moisture and to the sun'sradiation. The weathering agent can include, but is not limited to,asphalt, titanium dioxide, inert silicates and low clay, carbon black(lampblack) or other free carbon and an anti-settling agent. The asphaltmakeup of the weathering agent is typically about 60% to 80% by weightof the weathering agent, typically about 64% to 78% by weight of theweathering agent, and more typically about 68% by weight of theweathering agent. The amount of titanium oxide in the weathering agentis about 1% to 25% by weight of the weathering agent, and typicallyabout 19% by weight of the weathering agent. Typically, over 50% of thetitanium oxide is anatase grade. When carbon black is added to theweathering agent, the carbon black is present in an amount of up toabout 2% by weight of the weathering agent, typically about 0.5 to 1% byweight of the weathering agent, and more typically about 0.7% by weightof the weathering agent. The inert silicates and/or low clay, such as,but not limited to calcium borosilicate, when added to the weatheringagent, is present in an amount of about 8-11% by weight of theweathering agent. The antisettling agent, when added to the weatheringagent, is present in an amount of about 0.4-0.7% by weight of theweathering agent, and typically about 0.5% by weight of the weatheringagent. One specific formulation of the weathering agent includes about60-80 weight percent asphalt, about 1-25 weight percent titanium oxide,about 8-11 weight percent inert silicates and clay, about 0.5-2 weightpercent carbon black, about 0.4-0.7 weight percent anti-settling agent,and solvent. Another specific non-limiting formulation of the weatheringagent includes 65-75 weight percent gilsonite, 15-20 weight percenttitanium oxide, 8-11 weight percent calcium borosilicate, 0.5-1 weightpercent carbon black, 0.4-0.6 weight percent anti-settling agent, andsolvent. Still another specific non-limiting formulation of theweathering agent includes 64-78 weight percent gilsonite, 11.68-20.5weight percent titanium oxide, 8.4-10.3 weight percent inert silicatesand clay, 0.63-0.77 weight percent carbon black, 0.4-0.52 weight percentanti-settling agent, and solvent. Yet another non-limiting specificformulation of the weathering agent includes 70.86 weight percentgilsonite, 18.65 weight percent titanium oxide, 9.32 weight percentcalcium borosilicate, 0.7 weight percent carbon black, 0.47 weightpercent anti-settling agent, and solvent. A solvent such as, but notlimited to, naphthalene and/or paint thinners, is used to thin theweathering agent so that a thin, translucent or semi-translucent filmcan be formed on the surface of the metal alloy. The thickness of theweather agent layer is generally less than about 123 mils, moretypically about 6-123 microns, even more typically up to about 50microns, yet even more typically up to about 25 microns, and still moretypically about 12-25 microns. The color of the weathering agent istypically a dull, lackluster color which has low reflective properties.As a result, the weathering agent accelerates the patina formation onthe metal alloy coating and reduces the reflective properties of thenewly applied or formed metal alloy. Another type of weathering agentwhich can be used is disclosed in U.S. Pat. No. 5,296,300, which isincorporated herein.

[0178] When a sealant is applied to the coated metal strip, the sealantis typically used to provide additional protection to the coated metalalloy and/or coated base metal. The protective layer can be chromatefilm, phosphate coating, and/or an organic-inorganic composite film. Theprotective coating is typically formulated to have a high compatibilitywith the metal alloy layer. The protective layer is also typicallyformulated to cover imperfections in the metal alloy coating, and/or toprovided additional corrosion resistance to the metal alloy coating. Theprotective coating typically is has a thickness of about 1-150 microns,and typically about 1-50 microns. The protective layer is typicallydried by air drying and/or by heating lamps.

[0179] Metal strip 12 can be oxidized to partially or fully expose theheat created intermetallic layer prior to or subsequent to the coatedmetal strip being rolled into a metal roll, cut into sheets of strip,and/or formed into various shapes. To expose the heat createdintermetallic layer, the coated metal alloy can be ground off and/orchemically removed. Typically the metal alloy coating is chemicallyremoved by an oxidizing solution. As shown in FIG. 13, coated metalstrip is immersed in oxidizing solution 133 in oxidizing tank 132. Theoxidizing solution is formulated to at least partially removes the metalalloy coating from metal strip 12 thereby at least partially exposingheat created intermetallic layer 140. The intermetallic layer has beenfound in many environments to be an excellent corrosion resistant layer.Oxidation tank 132 is of sufficient length and depth to facilitatecomplete immersion of metal strip 12 in oxidation solution 133 and tomaintain the metal strip in contact with the oxidation solution for asufficient period of time. Typically, oxidation tank 132 is at leastabout 20 feet in length. As can be appreciated, the oxidation tank canbe longer or shorter depending on the speed of the metal strip.Furthermore, the oxidation tank can be designed so that only a portionof the surface of metal strip 12 contacts the oxidation solution. Theoxidation tank typically includes one or more agitators, not shown. Theagitators are designed to agitate oxidation solution 133 to maintain auniform solution concentration, maintain a uniform solution temperature,and/or break up gas pockets which form on the surface of metal strip 12.The agitators typically include an abrasive material which can bothagitate the oxidation solution and facilitate in the removal of themetal alloy on the surface of metal strip 12 when in contact with thesurface of the metal strip. The agitators are typically made of amaterial which does not react with oxidation solution 133 and resistsundue wear when in contact with the metal strip surface. The oxidizingsolution typically includes an acid such as, but not limited to, nitricacid. When nitric acid is included in the oxidation solution, the nitricacid concentration is generally about 5%-60% by volume and typicallyabout 10-25% by volume, more typically about 25% by volume, and evenmore typically about 20% by volume. Copper sulfate is generally added tothe acid in the oxidizing solution to improve the oxidation of the metalalloy coating. Copper sulfate, when present, is generally added in aconcentration of less than about 10% by volume, typically about 0.5-2%by volume, and more typically about 1% by volume. The temperature of theoxidizing solution is maintained at a temperature that providessufficient activity of the oxidizing solution. Generally, thetemperature is maintained between about 20-80° C., typically about30-80° C., more typically about 40-60° C., and even more typically about50° C.; however, other temperatures can be used. By increasing theconcentration and/or temperature of the oxidation solution, the timeneeded to at least partially remove the metal alloy coating 76 isshortened. Metal strip 12 is generally not exposed to the oxidationsolution for more than about 20 minutes, typically less than about tenminutes, more typically less than about two minutes, still moretypically about 0.08-1.5 minutes, and even more typically about 0.33minutes; however, longer oxidation times can be used depending on thetype of oxidation solution, concentration and temperature of theoxidation solution, type of metal alloy, and/or thickness of the metalalloy. The exposed heat created intermetallic layer is typically has adark grey, non-reflective surface. As can be appreciated, the oxidationsolution can be applied to the coated metal strip after or just prior tothe metal strip being formed and/or installed. In this instance, theoxidizing solution can be swabbed or sprayed onto the surface of thecoated metal strip.

[0180] Once the desired amount of metal alloy coating is removed, theexposed heat created intermetallic layer is typically passivated toenhance the corrosion-resistance of the intermetallic layer. Theintermetallic layer is generally passivated by a passivating solution.One type of passivating solution includes a nitrogen containing solutionand/or a chromium solution such as, but not limited to, nitric acidand/or chromate acid. The passivation solution can be the same as ordifferent from the oxidizing solution. When chromate acid is included inthe passivation solution, the concentration of chromate acid isgenerally about 0.5-5 g/liter. Phosphate can be added to the passivationsolution to enhance the passivation of the metal alloy. When thepassivation solution and the oxidizing solution are the same, theremoval of metal alloy coating and passivation of the heat createdintermetallic layer can both be accomplished in a single tank. In asingle tank arrangement, the passivation solution and the oxidizingsolution are formulated such that when the heat created intermetalliclayer is exposed and then passified, the passivated layer is not removedor very slowly removed by the passivation solution and the oxidizingsolution, thus making the oxidation and passivation processautocatalytic or semi-autocatalytic. As illustrated in FIG. 13, metalstrip 13 is directed into a passivation tank 135 after being oxidized inoxidation tank 132. The passivation tank 132 typically includes anagitator to prevent or reduce stagnation and/or vast concentrationdifferences of the passivation solution in the tank, prevent or reducegas bubbles from forming on the surface of metal strip 12, and/ormaintain a substantially uniform temperature for the passivationsolution. The temperature of the passivation solution is maintained at atemperature that provides sufficient activity of the passivationsolution. Generally, the temperature of the passivation solution ismaintained between about 15-80° C., typically about 40-60° C. Byincreasing the concentration and/or temperature of the passivationsolution, the time needed to at least partially passivate the exposedheat created intermetallic layer is shortened. The amount of time topassivate the heat created intermetallic layer is generally less thanabout ten minutes, and typically about 0.02-1.5 minutes; however, longertimes can be used.

[0181] Referring now to FIG. 14, passivation layer 146 is a very thinlayer. Generally, the thickness of the passivation layer is less thanabout 13 microns, typically less than about 3 microns, and moretypically up to about 1.5 microns. The passivation layer facilitates ininhibiting or preventing oxidation (i.e. white rust) of the outer metallayer. The passivation layer 146 can significantly enhance thecorrosion-resistance of the intermetallic layer 142. Although it is notentirely known how passivation layer 148 exhibits increased corrosionresistance, it is believed that a unique covalently bonded system isformed when the intermetallic layer is passified. When the intermetalliclayer 142 is passified with passivation solution 162, a chemicalreaction is believed to occur to modify the atomic structure ofpassivation layer 146. Other elements such as, but not limited to,nitrogen, hydrogen, oxygen may also be present in passivation layer 146to enhance the stability of passivation layer 146. The specialformulation of the intermetallic layer 142 in combination with thepassivation layer 146 provides for superior corrosion resistance formetal strip 12. Passivation layer 146 is typically malleable andgenerally does not crack when formed into various shapes. Passivationlayer 146 is generally a grey, earth tone color non-reflective surface.Passivation layer 146 displays increased corrosion resistance, abrasionresistance, and/or increased hardness as compared to the heat createdintermetallic layer. Heat created intermetallic layer 142 andpassivation layer 146 are generally resistant to scratching therebyimproving the visual quality of metal strip 12 and/or enhancing thedamage resistance of metal strip 12. The relative nonexistence of leadin intermetallic layer 142 and passivated layer, especially when lowlead metal alloys are used, makes the passivated metal strip a superiorsubstitute to terne coated materials. Not only is the corrosionresistance of the intermetallic layer and passivated layer greater thanterne coatings in many different environments, the intermetallic layerand the passivated layer contain little, if any, lead therebyalleviating any concerns associated with the use of lead materials.

[0182] After metal strip 12 is oxidized and/or passified, metal strip 12is typically rinsed to remove any oxidation solution and/or passivationsolution remaining of the metal strip. The rinse process can beperformed by liquid spray jets and/or immersion of the metal strip in atank that contains a rinse solution. Typically, the rinse liquid isabout ambient temperature. The rinse tank, when used, typically includesan agitator to assist in the removal of the oxidizing solution and/orpassivation solution from metal strip 12. Once the rinse process iscomplete, the metal strip is rolled into strip roll 150, cut into sheets130, preformed to various articles, and painted or sealed.

[0183] Referring now to FIGS. 16-18, a fuel tank is formed from coatedmetal strip 12. Fuel tank 160 is made up of two shell members 162 and164. As can be appreciated, the fuel tank can be made of more or lessmembers. The shell members are typically shaped in a die by placing thecoated metal strip or a section thereof on a die and drawing the coatedmetal strip over the die. As can be appreciated, the shell members canbe formed by other process such as, but not limited to, Hot Metal GasForming processes, Hydraulic Metal Forming process, etc. The shells aretypically formed in a cylindrical shape and each have a peripheral edge166; however, other shapes can be formed. The two shells are joinedtogether at the respective peripheral edges to form an inner fuelreceiving chamber 168 wherein the fuel is stored within the tank. Fueltank 160 also contains a spout 170 which communicates with interiorchamber 168 of the fuel tank so that the fuel can be inserted into theinner chamber. Typically, the spout is inserted at the top portion ofshell 162 for easy insertion of the fuel into the tank; however, thespout can be located in other areas. Fuel tank 160 also contains a drainhole 172 which communicates with the interior of the fuel tank chamberand the fuel system of a motor of a vehicle, boat, airplane, etc.Typically, drain hole 172 is located at the top of the fuel tank onshell 162; however, the drain hole can be located in other areas. A fuelpump can be located in the inner chamber of the fuel tank to pump thefuel out of and/or into the inner chamber.

[0184] As illustrated in FIG. 18, shell members 162 and 164 are joinedtogether by abutting and connecting together peripheral edges 166 of therespective shell members. Typically, the peripheral edges are connectedtogether a weld or solder 180; however, the peripheral edges can beconnected together by other or additional means. Spout 170 and drainhole 172 are also connected to the shell member typically by a weld orsolder; however, the spout and/or drain hole can be connected by otheror additional means. Generally, the weld or solder is essentiallylead-free so as not to add any lead to the fuel tank. Each shell memberincludes a corrosion resistant metal alloy coating 186 and an innercorrosion resistant metal alloy coating 188. Typically the thicknessesof the two coatings are the same. When the coated metal strip is drawnover the die, the corrosion resistant metal alloy coating 186,188becomes elongated about the peripheral edge corner 190. When corrosionresistant metal alloy coating is elongated, the corrosion resistantmetal alloy coating can reduce in thickness. If the corrosion resistantalloy coating is too thin, the alloy coating can tear or shear andexpose the unprotected surface of metal strip 12. Typically, thethickness of the corrosion resistant metal alloy coating is at leastabout 25 microns so that as the metal alloy coating can be elongated andshaped by the die with little, if any, incident of shearing and exposingthe surface of the base metal of the metal strip. Examples of fuel tanksthat can be used are disclosed in U.S. Pat. Nos. 5,827,618; 5,695,822;5,667,849; 5,616,424; 5,597,656; 5,491,036; 5,491,035; and 5,455,122,which are incorporated herein by reference.

[0185] Referring now to FIGS. 19-20, building materials such as roofingpanels are illustrated as being formed from the coated metal strip.Roofing panels P are joined together by an elongated standing seam S.Roofing panels P are typically formed on site or preformed in the shapeof elongated pans as shown in FIG. 19. Pans 200 and 202 are illustratedas having substantially similar features. Both pans have a right edgeportion 204 and a left edge portion 206. As shown in FIG. 20, pans 202and 204 are adjacently positioned together to define the elongateddirection D lying along base line X. A cleat 210 is used to form seal S.Nails 212 are typically used to maintain the pans on roof 220 while seamS is formed. In standing seam applications, the edges of the roofingmaterials are typically folded together and then soldered to form awater tight seal. The metal alloy coating inherently includes excellentsoldering characteristics. The metal alloy coating can be also welded orsoldered. Typical solders contain about 50% tin and about 50% lead;however, higher lead content solders can be used. The metal alloy hasthe added advantage of being solderable with low or no-lead solders. Theroofing materials can be used in mechanically joined roofing systems dueto the malleability of the metal alloy. Mechanically joined systems formwater tight seals by folding adjacent roof material edges together andsubsequently applying a compressive force to the seam which is typicallyin excess of about 1,000 psi. Under these high pressures, the metalalloy plastically deforms within the seam and produces a water tightseal. This type of roofing system is disclosed in U.S. Pat. Nos.4,934,120; 4,982,543; 4,987,716; 4,934,120; 5,001,881; 5,022,203;5,259,166; and 5,301,474, which are incorporated herein by reference.

[0186] Referring now to FIG. 21, a corrosion resistant metal alloy isformed into a metal alloy strip 230 by a roll forming process. As can beappreciated, the metal alloy can alternatively be formed into a wire, atube, or molded or cast into other shapes. Ingots of tin or tin and zincare typically placed into the melting pot 240 wherein the tin or the tinand zinc ingots are melted. The molten metal alloy is maintained aboveits melting point in the melting pot. Other metals such as, but notlimited to, iron, nickel, aluminum, titanium, copper, manganese,bismuth, antimony can be added into the melting pot to alter thecomposition of the metal alloy, and/or can be included due to impuritiesin the tin and/or zinc ingots. The inclusion of these other metalstypically alters the melting point of the metal alloy. In order toaccommodate for the high melting temperature of the metal alloy, themelting pot is made of materials to withstand such temperatures. Oncethe metal alloy is properly mixed and melted in melting pot 240, themolten alloy is allowed to flow out of the bottom of the melting potthrough pot opening 242. The molten metal alloy 230 is then directedthrough one or more sets of rollers 260 until the desired thickness ofthe metal alloy sheet or strip is obtained. The process of roll formingmetal strip is well known in the art, thus further details as to theforming of the metal alloy strip 230 will not be discussed. Thethickness of the formed metal alloy strip 230 is typically less thanabout 5080 microns. Once metal alloy strip 230 has passed throughrollers 260, metal alloy strip 230 may be further processed, such as bya pretreatment processes, a coating process, and/or a post coatingprocess as discussed above. As shown in FIG. 21, metal alloy strip 230is directed into a passivation tank 270. Passivation tank 270 includes apassivation solution 272. The passivation solution is typically the samepassivation solution as described above. As the metal alloy strip isdirected into passivation tank 270, guide rollers 280 guide the metalalloy strip. The passivation solution reacts with the surface of themetal alloy strip to form a passivation layer which is highly corrosionresistant. The passivation solution also causes the surface of the metalstrip to change colors. The passivation tank generally includes anagitator to prevent or inhibit stagnation and/or vast concentrationdifferences of the passivation solution in the passivation tank. Aftermetal alloy strip 230 passes through the passivation tank, the metalalloy strip typically proceeds to a rinsing process, not shown, toremove passivation solution remaining on the metal alloy strip.Generally, the passivation solution is removed by passing the metalalloy strip through a rinse tank and/or by spraying the metal alloystrip with a rinse fluid. As shown in FIG. 21, after metal alloy stripis passivated, the strip is rolled into a roll 290 of metal alloy strip.As can be appreciated, the molten metal alloy can alternatively beformed into a wire or tube. Such wire or tube can be used for pipes,wire, cable, solder or welding wire. When the metal alloy is formed intoa solder or welding wire, the metal alloy is generally not passivated.The solder or welding wire has been found to form a strong bond with themetal materials and has excellent wetting properties to create a highquality bond. The solder also has good conductive properties so that itcan be used to form electrical connections. The types of base metalswhich can be soldered by the metal alloy include, but are not limitedto, carbon steel, stainless steel, copper, copper alloys, aluminum,aluminum alloys, nickel alloys, tin, titanium, titanium alloys.Materials coated with tin, tin alloys, zinc, zinc alloys, tin and zincalloys, lead, lead and tin alloys, and various other metals can also besoldered or welded by the metal alloy. The metal alloy strip can also beformed into roofing materials and/or gasoline tanks, as described above,or a variety of components.

[0187] The corrosion resistant metal alloy described above is a tinalloy or a tin and zinc alloy. Both of these metal alloys exhibitexcellent bonding and corrosion resistant properties when applied to abase metal by a hot dip process and/or by a plating process.

[0188] The tin alloy is formulated to include at least a majority oftin. Generally, the tin alloy includes at least about 75 weight percenttin and less than about 10 weight percent zinc, and typically at leastabout 90 and less than about 10 weight percent zinc. In certain tinalloys, the tin content can at least about 95 weight percent tin, or atleast about 98 weight percent tin, or at least about 99 weight percenttin. The high percentage of tin in the tin alloy is substantiallydifferent from standard terne alloy formulations which contain about 80%lead and 20% tin. The high concentration of tin in the tin alloyincreases the uniformity and strength of the bond between the tin alloyand many types of metal strip 12 as compared with standard terne alloycoatings. The superior bonding characteristics of the tin alloy makesthe tin alloy coating ideal for use with many different types of metalstrip compositions, and can be formed in a variety of simple and complexshapes. Industrial grade tin typically is used as the tin source for thetin alloy; however, other sources of the tin can be used. Industrialgrade tin typically contains trace amounts of impurities such as, butnot limited to, cobalt, nickel, silver and sulphur. It has been foundthat these elements in controlled amounts do not adversely affect thecorrosive resistive properties of the tin alloy. Indeed, elements suchas, but not limited to, nickel can enhance some properties of the tinalloy.

[0189] The tin and zinc alloy is a special combination of tin and zinc.The tin and zinc alloy is formulated to include at least about 10 weightpercent zinc and at least about 15 weight percent tin and the majorityweight percent of the tin and zinc alloy includes tin and zinc. It hasbeen found that the addition of zinc in the amount of at least about 10weight percent of the tin and zinc alloy produces a metal alloy havingenhanced corrosion-resistance in various types of environments. The tincontent of the tin and zinc alloy is generally about 15-90 weightpercent. The zinc content of the alloy is generally about 10-85 weightpercent. The tin plus zinc content of the tin and zinc alloy typicallyconstitutes at least a majority of the tin and zinc alloy. Typically,tin plus zinc content of the tin and zinc alloy constitutes at leastabout 75 weight percent tin and zinc, more typically at least about 80weight percent tin and zinc, even more typically at least about 90weight percent tin and zinc, still even more typically at least about 95weight percent tin and zinc, yet still even more typically at leastabout 98 weight percent tin and zinc, and yet still even more typicallyat least about 99 weight percent tin and zinc. The tin and zincformulation typically oxidizes to form a colored coating which closelyresembles the popular grey, earth-tone color of weathered terne. The useof large weight percentages of zinc in the tin and zinc alloy has beenfound to not cause the coating to become too rigid or too brittle. Thetin and zinc alloy is formable thus can be, in many instances, bent intosimple or complex shapes without cracking or breaking. The malleabilityof tin and zinc alloy is believed to be at partially the result of theunique tin and zinc distributions within the tin and zinc alloy. The tinand zinc form a two phase matrix wherein zinc globules or crystals areat least partially surrounded by tin. Zinc facilitates in stabilizingthe tin in the tin and zinc alloy so as to inhibit or prevent tincrystallization in the tin and zinc alloy. When determining thecomposition of the tin and zinc alloy, the environment the coating is tobe used in should be considered. In some situations, a higher tinconcentration may be beneficial to limit the amount of zinc richglobules or crystals in the tin and zinc alloy. In other environments,the reverse may be true.

[0190] The tin alloy or the tin and zinc alloy typically contains one ormore additives without adversely affecting the tin alloy or the tin andzinc alloy; however, the addition of additives is not required. Theadditives are included and/or added to tin alloy or the tin and zincalloy to modify the mechanical properties of the metal alloy, thecorrosion-resistance of the metal alloy, the color of the corrosionresistant metal alloy, the stability of the metal alloy, and/or thecoating properties of the metal alloy. The additive(s) generallyconstitute less than about 25 weight percent of the metal alloy.Typically, the additive(s) constitute less than about 10 weight percentof the metal alloy. The content of the additives is controlled so thatthe additives properly mix with the metal alloy. The proper mixing ofthe additives in the metal alloy is of greater importance for a tin andzinc alloy wherein the tin and zinc form a special two phase matrix.Typically, the additives are added to a tin and zinc alloy in a mannerthat maintains the two phase matrix of the tin and zinc so as not toform a tin and zinc alloy having more than two phases or which disruptsthe tin and zinc matrix.

[0191] The tin alloy typically includes at least an effective amount ofone or more stabilizing additives to inhibit or prevent the tin fromcrystallizing. The tin and zinc alloy can also include stabilizingadditives; however, such additives can be eliminated since the zinc inthe tin and zinc alloy generally facilitates in stabilizing the tin toinhibit or prevent the tin from crystallizing. Tin can begin tocrystallize when the temperature drops below about 13° C.Crystallization of the tin in the alloy can weaken the bond between themetal strip and the metal alloy and can result in flaking of the metalalloy from the metal strip. The addition of small amounts of stabilizingmetals such as, but not limited to, antimony, bismuth, cadmium, copper,zinc and mixtures thereof prevent and/or inhibit the crystallization ofthe tin in the metal alloy. Only small amounts of one or more of thesemetals is needed to stabilize the tin in the metal alloy and inhibitand/or prevent the tin from crystallizing. Amounts of at least about0.001-0.01 weight percent of the metal alloy are generally sufficient toinhibit or prevent tin crystallization. Typically, the one or morestabilizing metals are included in an amount of at least about0.001-0.005 weight percent of the metal alloy to inhibit crystallizationof the tin.

[0192] The tin alloy or tin and zinc alloy can include other additivesto alter and/or enhance one or more properties of the metal alloy. Themetal alloy can include at least an effective amount ofcorrosion-resistant agent to enhance the corrosion-resistant propertiesof the metal alloy. The corrosion-resistant agent includes, but is notlimited to, antimony, bismuth, cadmium, chromium, copper, lead,manganese, magnesium, nickel, titanium and/or zinc. The metal alloy caninclude at least an effective amount of coloring agent to alter thecolor of the metal alloy. The coloring agent includes, but is notlimited to, cadmium, copper, iron, lead, silver and/or titanium. Themetal alloy can include at least an effective amount of reflective agentto positively alter the reflectiveness of said metal alloy. Thereflective agent includes, but is not limited to, aluminum, cadmium,chromium, copper, silver and/or titanium. A metal alloy which includes asufficient amount of coloring agents and/or reflective agent may not berequired to be weathered or weathered as long prior to use in certainapplications. The metal alloy can include at least an effective amountof grain agent to positively alter the grain density of the metal alloy.The grain agent includes, but is not limited to, cadmium, manganeseand/or titanium. The metal alloy can include at least an effectiveamount of mechanical agent to positively alter the mechanical propertiesof the metal alloy. The mechanical properties of the metal alloyinclude, but are not limited to, the strength of the metal alloy, thehardness of the metal alloy, the pliability of the metal alloy, theelongation of the metal alloy, the tensile strength of the metal alloy,the elasticity of the metal alloy, the rigidity of the metal alloy, theconductivity of the metal alloy, the heat transfer properties of themetal alloy, etc. The mechanical agent includes, but is not limited to,aluminum, antimony, arsenic, bismuth, cadmium, chromium, copper, iron,lead, magnesium, manganese, nickel, silver, titanium, and/or zinc. Themetal alloy can include at least an effective amount of deoxidizingagent to reduce the amount of oxidation of the metal alloy in a moltenstate. The deoxidizing agent includes, but is not limited to, aluminum,cadmium, magnesium, manganese and/or titanium. The metal alloy caninclude at least an effective amount of bonding agent to enhance thebonding properties of the metal alloy to the metal strip and/orintermediate barrier metal layer. The bonding agent includes, but is notlimited to, cadmium, lead, manganese, titanium and/or zinc.

[0193] Aluminum, if added to and/or included in the metal alloy, isgenerally present in amounts up to about 5 weight percent of the metalalloy; however, higher weight percentages can be used. In severalaspects of the present invention, the aluminum content of the metalalloy is a) up to about 2 weight percent of the metal alloy, b) up toabout 1 weight percent of the metal alloy, c) up to about 0.75 weightpercent of the metal alloy, d) up to about 0.5 weight percent of themetal alloy, f) up to about 0.4 weight percent of the metal alloy, g) upto about 0.3 weight percent of the metal alloy, h) up to about 0.25weight percent of the metal alloy, i) at least about 0.05 weight percentof the metal alloy, j) about 0.1-1 weight percent of the metal alloy, k)about 0.1-0.5 weight percent of the metal alloy, l) about 0.1-0.3 weightpercent of the metal alloy, m) about 0.01-1 weight percent of the metalalloy, n) about 0.01-0.5 weight percent of the metal alloy, o) about0.01-0.3 weight percent of the metal alloy, p) about 0.01-0.1 weightpercent of the metal alloy, q) about 0.0005-0.75 weight percent of themetal alloy, r) about 0.001-0.5 weight percent of the metal alloy, s)about 0.001-0.4 weight percent of the metal alloy, t) about 0.002-0.4weight percent of the metal alloy, u) about 0.001-0.4 weight percent ofthe metal alloy, v) about 0.001-0.01 weight percent of the metal alloy,and w) about 0.0001-0.005 weight percent of the metal alloy, x) about0.001-0.005 weight percent of the metal alloy, and y) less than about0.001 weight percent of the metal alloy. When aluminum is added to themetal alloy, the aluminum is typically added in the form of an alloysuch as, but not limited to, Al—Cu—Mg alloy.

[0194] Antimony, if added to and/or included in the alloy, is generallypresent in amounts up to about 7.5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the antimony content of the metal alloy is a) upto about 5.5 weight percent of the metal alloy, b) up to about 2.5weight percent of the metal alloy, c) up to about 2 weight percent ofthe metal alloy, d) up to about 1 weight percent of the metal alloy, e)up to about 0.75 weight percent of the metal alloy, f) up to about 0.5weight percent of the metal alloy, g) about 0.001-1 weight percent ofthe metal alloy, h) about 0.005-0.8 weight percent of the metal alloy,i) about 0.01-0.8 weight percent of the metal alloy, j) about 0.01-0.5weight percent of the metal alloy, and k) about 0.05-0.5 weight percentof the metal alloy.

[0195] Bismuth, if added to and/or included in the metal alloy, isgenerally present in amounts up to about 1.7 weight percent of the metalalloy; however, higher weight percentages can be used. In severalaspects of the present invention, the bismuth content of the metal alloyis a) up to about 1 weight percent of the metal alloy b) up to about 0.5weight percent of the metal alloy, c) up to about 0.01 weight percent ofthe metal alloy, d) about 0.0001-0.5 weight percent of the metal alloy,e) about 0.05-0.5 weight percent of the metal alloy, f) about 0.0001-0.2weight percent of the metal alloy, g) about 0.002-0.1 weight percent ofthe metal alloy, and h) about 0.001-0.01 weight percent of the metalalloy.

[0196] Cadmium, if added and/or included in the metal alloy, is presentin amounts of up to about 0.5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the cadmium content of the metal alloy is a) upto about 0.1 weight percent of the metal alloy, and b) less than about0.05 weight percent of the metal alloy.

[0197] Chromium, if added and/or included in the metal alloy, is presentin amounts of at least about 0.0001 weight percent. In several aspectsof the present invention, the chromium content of the metal alloy is a)less than about 0.1 weight percent of the metal alloy, and b) up toabout 0.02 weight percent of the metal alloy.

[0198] Copper, if added to and/or included in the metal alloy, ispresent in amounts up to about 5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the copper content of the metal alloy is a) up toabout 2.7 weight percent of the metal alloy, b) up to about 2 weightpercent of the metal alloy, c) up to about 1.6 weight percent of themetal alloy, d) up to about 1.5 weight percent of the metal alloy, e) upto about 1 weight percent of the metal alloy, f) up to about 0.05 weightpercent of the metal alloy, g) at least about 0.001 weight percent ofthe metal alloy, h) at least about 0.1 weight percent of the metalalloy, i) about 0.001-2.7 weight percent of the metal alloy, j) about0.01-2.7 weight percent of the metal alloy, k) about 0.001-1.6 weightpercent of the metal alloy, l) about 0.1-1.6 weight percent of the metalalloy, m) about 1-1.5 weight percent of the metal alloy, n) about0.001-1 weight percent of the metal alloy, o) about 0.001-0.5 weightpercent of the metal alloy, p) about 0.005-0.6 weight percent of themetal alloy, q) about 0.005-0.1 weight percent of the metal alloy, r)about 0.01-0.1 weight percent of the metal alloy, s) about 0.05-0.1weight percent of the metal alloy, t) about 0.005-2.7 weight percent ofthe metal alloy, u) about 0.005-1.6 weight percent of the metal alloy,and v) about 0.1-1.5 weight percent of the metal alloy. When copper isadded to the metal alloy, the copper is typically added in the form ofbrass and/or bronze.

[0199] Iron, if added to and/or included in the metal alloy, is added inamounts up to about 1 weight percent of the metal alloy; however, higherweight percentages can be used. In several aspects of the presentinvention, the iron content of the metal alloy is a) less than about 0.5weight percent of the metal alloy, b) less than about 0.1 weight percentof the metal alloy, c) up to about 0.02 weight percent of the metalalloy, d) less than about 0.01 weight percent of the metal alloy, e)less than about 0.005 weight percent of the metal alloy, and f) lessthan about 0.002 weight percent of the metal alloy.

[0200] Lead, if added to and/or included in the metal alloy, is presentin low levels, generally less than about 10 weight percent of the metalalloy; however, higher weight percentages can be used. In severalaspects of the present invention, the lead content of the metal alloy isa) less than about 2 weight percent of the metal alloy, b) less thanabout 1 weight percent of the alloy, c) less than about 0.5 weightpercent of the alloy, d) less than about 0.1 weight percent of the metalalloy, e) less than about 0.075 weight percent of the metal alloy, f)less than about 0.06 weight percent of the metal alloy, g) less thanabout 0.05 weight percent of the metal alloy, h) less than about 0.02weight percent of the metal alloy; i) less than about 0.01 weightpercent of the metal alloy, j) less than about 0.001 weight percent ofthe metal alloy, and k) about 0.001-0.1 weight percent.

[0201] Magnesium, if added to and/or included in the metal alloy, ispresent in amounts up to about 5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the magnesium content of the metal alloy is a) upto about 2 weight percent of the metal alloy, b) up to about 1 weightpercent of the metal alloy, c) up to about 0.4 weight percent of themetal alloy, d) up to about 0.1 weight percent of the metal alloy, e)about 0.1-0.4 weight percent of the metal alloy, f) about 0.01-0.4weight percent of the metal alloy, and g) about 0.001-0.1 weight percentof the metal alloy. When magnesium is added to the metal alloy, themagnesium is typically added in the form of pure magnesium.

[0202] Manganese, if added to and/or included in the metal alloy, ispresent in amounts up to about 0.1 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the manganese content of the metal alloy is a) atleast about 0.0001 weight percent of the metal alloy, b) up to about0.01 weight percent of the metal alloy, c) about 0.0001-0.1 weightpercent of the metal alloy, d) about 0.001-0.1 weight percent of themetal alloy, and e) about 0.0001-0.01 weight percent of the metal alloy.

[0203] Nickel, if added to and/or included in the metal alloy, ispresent in amounts up to about 5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the nickel content of the metal alloy is a) up toabout 2 weight percent of the metal alloy, b) up to about 1 weightpercent of the metal alloy, c) up to about 0.9 weight percent of themetal alloy, d) up to about 0.7 weight percent of the metal alloy; e) upto about 0.3 weight percent of the metal alloy, f) up to about 0.1weight percent of the metal alloy, g) up to about 0.005 weight percentof the metal alloy, h) about 0.001-0.1 weight percent of the metalalloy, i) about 0.001-0.9 weight percent of the metal alloy, j) about0.001-0.3 weight percent of the metal alloy, k) about 0.001-0.05 weightpercent of the metal alloy, 1) about 0.001-0.005 weight percent of themetal alloy, and m) about 0.01-0.7 weight percent of the metal alloy.

[0204] Titanium, if added to and/or included in the metal alloy, ispresent in amounts up to about 1 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the titanium content of the metal alloy is a) upto about 0.5 weight percent of the metal alloy, b) up to about 0.2weight percent of the metal alloy, c) up to about 0.18 weight percent ofthe metal alloy; d) up to about 0.15 weight percent of the metal alloy;e) up to about 0.1 weight percent of the metal alloy, f) up to about0.075 weight percent of the metal alloy, g) up to about 0.05 weightpercent of the metal alloy, h) at least about 0.0005 weight percent ofthe metal alloy, i) about 0.01-0.5 weight percent of the metal alloy, j)about 0.01-0.15 weight percent of the metal alloy, k) about 0.0001-0.075weight percent of the metal alloy, l) about 0.0005-0.05 weight percentof the metal alloy, m) about 0.0005-0.18 weight percent of the metalalloy; n) about 0.001-0.05 weight percent of the metal alloy, and o)about 0.005-0.02 weight percent of the metal alloy. When titanium isadded to a tin and zinc alloy, the titanium is typically added as analloy such as, but not limited to, a Zn—Ti alloy.

[0205] Zinc, if added to and/or included in the tin alloy, is present inamounts up to about 9-10 weight percent of the metal alloy. Higherweight percentages of zinc transforms the metal alloy to a tin and zincalloy. In several aspects of the present invention, the zinc content ofthe tin alloy is a) up to about 8 weight percent of the tin alloy, b) upto about 7 weight percent of the tin alloy, c) up to about 1.5 weightpercent of the tin alloy, d) less than about 1 weight percent of the tinalloy, e) up to about 0.5 weight percent of the tin alloy, f) about0.001-0.5 weight percent of the tin alloy, and g) less than about 0.2weight percent of the tin alloy.

[0206] A general formulation of the corrosion resistant tin alloy byweight percent includes the following: Tin 75-99.99 Antimony  0-7.5Bismuth  0-1.7 Copper  0-5 Lead  0-10

[0207] A more specific formulation of the corrosion resistant tin alloyby weight percent includes the following: Tin 75-99.99 Aluminum  0-5Antimony  0-7.5 Bismuth  0-1.7 Copper  0-5 Lead  0-10 Nickel  0-5 Zinc 0-9

[0208] Another and/or alternative more specific formulation of thecorrosion resistant tin alloy by weight percent includes the following:Tin 90-99.99 Aluminum  0-2 Antimony  0-2 Arsenic  0-0.05 Bismuth  0-1.5Boron  0-0.1 Cadmium  0-0.5 Carbon  0-1 Chromium  0-1 Copper  0-2 Iron 0-1 Lead  0-2 Magnesium  0-1 Manganese  0-0.1 Molybdenum  0-0.1 Nickel 0-1 Silicon  0-0.5 Silver  0-0.1 Tellurium  0-0.05 Titanium  0-0.5Vanadium  0-0.1 Zinc  0-7

[0209] Still another and/or alternative more specific formulation of thetin alloy by weight percent includes the following: Tin 90-99.9 Aluminum 0-5 Antimony  0-7.5 Arsenic  0-0.005 Bismuth  0-1.7 Boron  0-0.1Cadmium  0-0.1 Carbon  0-1 Chromium  0-1 Copper  0-5 Iron  0-1 Lead  0-2Magnesium  0-5 Manganese  0-0.1 Molybdenum  0-0.1 Nickel  0-5 Silicon 0-0.5 Silver  0-0.005 Tellurium  0-0.05 Titanium  0-1 Vanadium  0-0.1Zinc  0-9

[0210] A few examples of the metal alloy composition by weight percentwhich have exhibited the desired characteristics as mentioned above areset forth as follows: Alloy Ingredients A B C D E Tin Bal. Bal. Bal.Bal. Bal. Aluminum ≦0.01 ≦0.01 ≦0.05 0 0 Antimony ≦1 ≦0.1 ≦0.1 ≦0.05≦0.05 Bismuth ≦0.05 ≦0.05 ≦0.01 ≦0.01 ≦0.01 Copper ≦0.5 ≦0.05 0 1 0 Iron≦0.1 ≦0.005 0 0 0 Lead ≦1 ≦0.1 ≦0.1 ≦0.1 ≦2 Nickel ≦0.005 ≦0.05 ≦0.05≦0.005 ≦0.05 Zinc ≦1 ≦2 ≦3 ≦0.5 ≦1 Alloy Ingredients F G H I J Tin Bal.Bal. Bal. Bal. Bal. Aluminum ≦0.01 ≦0.01 0 0 ≦0.05 Antimony ≦0.1 ≦0.01≦0.05 ≦0.05 ≦0.1 Bismuth ≦0.05 ≦0.01 ≦0.01 ≦0.01 ≦0.1 Copper ≦0.5 0 0 0≦0.5 Iron ≦0.005 0 0 0 ≦0.05 Lead ≦0.1 ≦0.1 ≦0.1 ≦0.05 ≦1 Nickel 0 0 0 0≦1 Zinc ≦1 ≦1 ≦1 ≦1 ≦9 Alloy Ingredients K L M N O Tin Bal. Bal. Bal.Bal. Bal. Aluminum ≦0.01 ≦0.01 ≦0.05 0.0 0.0 Antimony ≦1.0 ≦0.1 ≦0.1≦0.05 ≦0.05 Bismuth ≦0.05 ≦0.05 ≦0.01 ≦0.01 ≦0.01 Copper ≦0.5 ≦0.5 0.01.0 0.0 Iron ≦0.1 ≦0.005 ≦0.0 ≦0.0 ≦0.0 Lead ≦1.0 ≦0.1 ≦0.1 ≦0.1 ≦2.0Nickel ≦0.005 ≦0.0 ≦0.0 ≦0.005 ≦0.0 Zinc ≦1 ≦2 ≦3 ≦0.5 ≦1

[0211] One formulation of the corrosion resistant tin alloy includes byweight percent at least 75% tin; 0-1% aluminum; 0-2% antimony; 0-0.02%arsenic; 0-1.5% bismuth; 0-0.1% boron; 0-0.1% cadmium; 0-0.5% carbon;0-0.5% chromium; 0-2% copper; 0-1% iron; 0-2% lead; 0-0.4% magnesium;0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.05% silicon;0-0.1% silver; 0-0.02% sulfur; 0-0.04% tellurium; 0-0.15% titanium;0-0.1% vanadium; and 0-9% zinc. Another and/or alterative formulation ofthe corrosion resistant tin alloy includes 90-99.9% tin; 0-0.5%aluminum; 0-2% antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron;0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron;0-1% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1%nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.01% sulfur; 0-0.01%tellurium; 0-0.15% titanium; 0-0.1% vanadium; and 0-9% zinc. Stillanother and/or alterative formulation of the corrosion resistant tinalloy includes at least 90% tin; 0-1% aluminum; 0-2% antimony; 0-0.02%arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.5% carbon;0-0.5% chromium; 0-2% copper; 0-1% iron; 0-2% lead; 0-0.4% magnesium;0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.05% silicon;0-0.05% silver; 0-0.02% sulfur; 0-0.04% tellurium; 0-0.15% titanium;0-0.05% vanadium; and 0-5% zinc. Yet another and/or alterativeformulation of the corrosion resistant tin alloy includes 95-99.99% tin;0-0.4% aluminum; 0-0.8% antimony; 0-0.005% arsenic; 0-0.5% bismuth;0-0.1% boron; 0-0.05% cadmium; 0-0.1% carbon; 0-0.05% chromium; 0-1%copper; 0-1% iron; 0-5% lead; 0-0.01% magnesium; 0-0.01% manganese;0-0.05% molybdenum; 0-0.9% nickel; 0-0.5% silicon; 0-0.01% silver;0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium; 0-0.01% vanadium;and 0-2% zinc. Still yet another and/or alterative formulation of thecorrosion resistant tin alloy includes 95-99.99% tin; 0-0.4% aluminum;0-0.8% antimony; 0-0.005% arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05%cadmium; 0-0.1% carbon; 0-0.05% chromium; 0-1% copper; 0-0.5% iron;0-0.5% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.05% molybdenum;0-0.9% nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01%tellurium; 0-0.1% titanium; 0-0.01% vanadium; and 0-2% zinc. A furtherand/or alterative formulation of the corrosion resistant tin alloyincludes 98-99.9% tin; 0-0.01% aluminum; 0-1% antimony and/or bismuth;0-0.1% copper; 0-0.05% iron; 0-0.5% lead; 0-0.05% magnesium; 0-0.05%manganese; 0-0.1% nickel; and 0-0.1% zinc. Yet a further and/oralterative formulation of the corrosion resistant tin alloy includes98-99.99% tin; 0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001%arsenic; 0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01%chromium; 0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium;0-0.001% manganese; 0-0.001% molybdenum; 0-0.9% nickel; 0-0.001%silicon; 0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05%titanium; 0-0.001% vanadium; and 0-1% zinc. Still yet a further and/oralterative formulation of the corrosion resistant tin alloy includes atleast 90% tin and 0.01-0.1% lead. Another and/or alterative formulationof the corrosion resistant tin alloy includes 90-99.9% tin and0.001-0.1% lead. Still another and/or alterative formulation of thecorrosion resistant tin alloy includes 90-99.9% tin; 0-7.5% antimony;0-1.7% bismuth; 0-2.7% copper; 0.001-0.1% lead; and 0-1.5% zinc. Yetanother and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; less than 0.001% aluminum; 0-7.5% antimony;0-1.7% bismuth; less than 0.05% cadmium; 0-2.7% copper; 0.001-0.1% lead;and 0-1.5% zinc. Still yet another and/or alterative formulation of thecorrosion resistant tin alloy includes 90-99.9% tin; 0-2.5% antimony;0-0.5% bismuth; 0-2.7% copper; 0-0.1% iron; 0.001-0.10% lead; and0.5-1.5% zinc. A further and/or alterative formulation of the corrosionresistant tin alloy includes 90-99.9% tin; 0-7.5% antimony; 0-1.7%bismuth; 0-2.7% copper; 0-0.1% iron; 0.01-0.1% lead; and 0-1.5% zinc.Yet a further and/or alterative formulation of the corrosion resistanttin alloy includes 90-99.95% tin; 0-7.5% antimony; 0-1.7% bismuth;0-2.7% copper; 0-1% iron; 0-0.5% lead; and 0-0.5% zinc. Still a furtherand/or alterative formulation of the corrosion resistant tin alloyincludes 90-99.95% tin; 0-7.5% antimony; 0-1.7% bismuth; 0-5% copper;0-1% iron; 0-0.5% lead; and 0-7% zinc. Still yet a further and/oralterative formulation of the corrosion resistant tin alloy includes90-99.95% tin; 0-0.5% antimony and/or bismuth; 0-1% copper; 0-1% iron;0-0.05% lead; and 0-1.5% zinc. Another and/or alterative formulation ofthe corrosion resistant tin alloy includes 90-99.95% tin; 0.005-0.5%antimony; bismuth and/or copper; 0-0.05% lead; and 0-0.5% zinc. Stillanother and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-5% aluminum; 0-7.5% antimony; 0-0.005%arsenic; 0-1.7% bismuth; 0-0.1% cadmium; 0-5% copper; 0-1% iron; 0-2%lead; 0-5% magnesium; 0-5% nickel; 0-0.005% silver; 0-1% titanium; and0-9% zinc. Yet another and/or alterative formulation of the corrosionresistant tin alloy includes 95-99.9% tin; 0-0.01% aluminum; 0-0.5%antimony; 0-0.5% bismuth; 0-0.005% iron; 0-0.1% lead; 0-0.1% nickel; and0-2% zinc. Still yet another and/or alterative formulation of thecorrosion resistant tin alloy includes 199-99.9% tin; 0-0.4% antimony;0-0.2% bismuth; 0-0.001% iron; 0-0.05% lead; 0-0.001% nickel; and 0-0.2%zinc. A further and/or alterative formulation of the corrosion resistanttin alloy includes 90-99.9% tin; 0-0.01% aluminum; 0-1% antimony;0-0.05% bismuth; 0-0.5% copper; 0-0.1% iron; 0-1% lead; 0-0.005% nickel;and 0-1% zinc. Yet a further and/or alterative formulation of thecorrosion resistant tin alloy includes 90-99.9% tin; 0-0.5% aluminum;0-2% antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1%cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; up to 1% iron;less than 1% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.01% sulfur;0-0.01% tellurium; 0-0.15% titanium; 0-0.1% vanadium; and 0-9% zinc.Still a further and/or alterative formulation of the corrosion resistanttin alloy includes 98-99.9% tin; 0-0.01% aluminum; 0-1% antimony and/orbismuth; 0-0.1% copper; less than 0.05% iron; less than 0.5% lead;0-0.05% magnesium; 0-0.05% manganese; 0-0.1% nickel; and 0-0.1% zinc.Still yet a further and/or alterative formulation of the corrosionresistant tin alloy includes 99-99.9% tin; 0.001-0.8% antimony and/orbismuth; 0-0.02% copper; 0-0.001% iron; and 0-0.08% lead; 0-0.001%nickel; and 0-0.001% zinc. Another formulation of the corrosionresistant tin alloy includes 90-99.9% tin; 0-5% aluminum; 0-7.5%antimony; 0-0.005% arsenic; 0-1.7% bismuth; 0-0.005% cadmium; 0-5%copper; 0-1% iron; 0-2% lead; 0-5% magnesium; 0-5% nickel; 0-0.005%silver; 0-1% titanium; and 0-9% zinc. Yet another and/or alterativeformulation of the corrosion resistant tin alloy includes 95-99.9% tin;0-0.05% aluminum; 0-0.2% antimony; 0-0.1% bismuth; 0-0.1% copper; 0-0.1%iron; 0-0.2% lead; 0-0.1% nickel; and 0-9% zinc. Still yet anotherand/or alterative formulation of the corrosion resistant tin alloyincludes 75-99.9% tin; 0-5% aluminum; 0-7.5% antimony; 0-1.7% bismuth;0-5% copper; 0-10% lead; 0-5% nickel; 0-0.5 titanium; and 0-9% zinc. Afurther and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-2% aluminum; 0-2% antimony; 0-0.05%arsenic; 0-1.5% bismuth; 0-0.1% boron; 0-0.5% cadmium; 0-1% carbon; 0-1%chromium; 0-2% copper; 0-1% iron; 0-2% lead; 0-1% magnesium; 0-0.1%manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.1%silver; 0-0.05% tellurium; 0-0.5% titanium; 0-0.1% vanadium; and 0-7%zinc. Yet a further and/or alterative formulation of the corrosionresistant tin alloy includes at least 90% tin; 0-1% aluminum; 0-2%antimony; 0-0.02% arsenic; 0-1.5% bismuth; 0-0.5% boron; 0-0.1% cadmium;0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron; 0-2% lead;0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel;0-0.05% silicon; 0-0.05% silver; 0-0.02% sulfur; 0-0.04% tellurium;0-0.15% titanium; 0-0.05% vanadium; and 0-5% zinc. Still a furtherand/or alterative formulation of the corrosion resistant tin alloyincludes 95-99.99% tin; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005%arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium; 0-0.1% carbon;0-0.05% chromium; 0-1% copper; 0-0.5% iron; 0-0.5% lead; 0-0.01%magnesium; 0-0.01% manganese; 0-0.05% molybdenum; 0-0.3% nickel; 0-0.01%silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1%titanium; 0-0.01% vanadium; and 0-2% zinc. Still yet a further and/oralterative formulation of the corrosion resistant tin alloy includes98-99.99% tin; 0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001%arsenic; 0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01%chromium; 0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium;0-0.001% manganese; 0-0.001% molybdenum; 0-0.1% nickel; 0-0.001%silicon; 0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05%titanium; 0-0.001% vanadium; and 0-1% zinc. Another and/or alterativeformulation of the corrosion resistant tin alloy includes at least 75%tin; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5% bismuth;0-0.05% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2%copper; 0-1% iron; 0-2% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-1% nickel; 0-0.05% silicon; 0-0.1% silver; 0-0.02% sulfur;0-0.04% tellurium; 0-0.15% titanium; 0-0.1% vanadium; and 0-9% zinc. Yetanother and/or alterative formulation of the corrosion resistant tinalloy includes 95-99.99% tin; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005%arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium; 0-0.1% carbon;0-0.05% chromium; 0-1% copper; 0-1% iron; 0-5% lead; 0-0.01% magnesium;0-0.01% manganese; 0-0.05% molybdenum; 0-0.9% nickel; 0-0.5% silicon;0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium;0-0.01% vanadium; and 0-2% zinc. Still another and/or alterativeformulation of the corrosion resistant tin alloy includes 98-99.99% tin;0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic;0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01% chromium;0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium; 0-0.001%manganese; 0-0.001% molybdenum; 0-0.9% nickel; 0-0.001% silicon;0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium;0-0.001% vanadium; and 0-1% zinc. Still yet another and/or alterativeformulation of the corrosion resistant tin alloy includes 90-99.9% tin;0-0.5% antimony; 0-1.5% bismuth; 0.00-1% lead; and 0-0.001% zinc. Afurther and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5% bismuth; 0-0.1%iron; 0-1% lead; and 0-0.5% zinc. Yet a further and/or alterativeformulation of the corrosion resistant tin alloy includes 90-99.9% tin;0-7.5% antimony; 0-2.7% copper; and 0-1% lead. Still a further and/oralterative formulation of the corrosion resistant tin alloy includes90-99.9% tin; 0-2.5% antimony; 0-2% copper; 0-1% lead; and 0-0.5% zinc.Still yet a further and/or alterative formulation of the corrosionresistant tin alloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5%bismuth; 0-0.1% iron; 0-1% lead; and 0-0.5% zinc. Another and/oralterative formulation of the corrosion resistant tin alloy includes90-99.9% tin; 0-1% antimony; 0-0.5% bismuth; 0-0.1% iron; and 0-1% lead.Still another and/or alterative of the corrosion resistant tin alloyincludes 90-99.9% tin; 0-0.5% bismuth; 0-0.1% iron; and 0-1% lead. Yetanother and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5% bismuth; 0-0.01%iron; 0.001-0.05% lead; and 0-0.5% zinc. Still yet another and/oralterative formulation of the corrosion resistant tin alloy includes90-99.9% tin; 0-0.5% antimony; 0-1.7% bismuth; 0-0.02% lead; and0-0.001% zinc. A further and/or alterative formulation of the corrosionresistant tin alloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5%bismuth; 0-0.005% cobalt; 0-2.7% copper; 0-0.1% iron; 0-0.05% lead;0-0.005% nickel; 0-0.001% silver; 0-0.001% sulfur; and 0-0.5% zinc.Still a further and/or alterative formulation of the corrosion resistanttin alloy includes 90-99.9% tin; 0-7.5% antimony; and 0-2.7% copper. Yeta further and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-2.5% antimony; 0-2% copper; and 0-0.5%zinc. Still yet a further and/or alterative formulation of the corrosionresistant tin alloy includes 90-99.9% tin; 0-0.5% antimony; 0-1.5%bismuth; 0-0.005% cobalt; 0-0.02% lead; 0-0.005% nickel; 0-0.001%silver; 0-0.001% sulfur; and 0-0.001% zinc. Another formulation of thecorrosion resistant tin alloy includes 90-99.9% tin and 0-0.1% lead.Still another and/or alterative formulation of the corrosion resistanttin alloy includes 90-99.9% tin and 0-0.01% lead. Yet another and/oralterative formulation of the corrosion resistant tin alloy includes90-99.9% tin; 0-5.5% antimony; 0-0.5% aluminum; 0-1.7% bismuth; 0-2.7%copper; 0-0.4% magnesium; 0-1% nickel; and 0-0.15% titanium. Still yetanother and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5% bismuth; 0-0.005%cobalt; 0-2.7% copper; 0-0.1% iron; 0-0.05% lead; 0-0.005% nickel;0-0.001% silver; 0-0.001% sulfur; and 0-0.5% zinc. A further and/oralterative formulation of the corrosion resistant tin alloy includes90-95% tin; 0-0.25% aluminum; 0-1.5% copper; 0-0.02% chromium; 0-0.01%iron; 0-0.01% lead; 0-0.01% manganese; 0-0.018% titanium; and 0-9% zinc.Still a further and/or alterative formulation of the corrosion resistanttin alloy includes 0-2.5% antimony, 0-0.5% bismuth, 0-2.7% copper;0-0.1% iron; 0.001-0.1% lead; 0.5-1.5% zinc and the remainder tin.Another and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-7.2% antimony; 0-1.7% bismuth; 0-2.7%copper; 0-0.1% iron; 0.001-0.1% lead; and 0-1.5% zinc. Still anotherand/or alterative formulation of the corrosion resistant tin alloyincludes at least about 95% tin; 0.001-0.1% lead, and at least about0.5% stabilizer. Yet another and/or alterative formulation of thecorrosion resistant tin alloy includes 0-2.5% antimony, 0-0.5% bismuth,0-2.7% copper, 0-0.1% iron, 0.001-0.1% lead, 0-1.5% zinc and theremainder tin. Still yet another and/or alterative formulation of thecorrosion resistant tin alloy includes 90-99.95% tin; 0-7.2% antimony;0-1.7% bismuth; 0-2.7% copper; 0-0.1% iron; 0.001-0.1% lead; and 0-0.5%zinc. A further and/or alterative formulation of the corrosion resistanttin alloy includes 90-99.95% tin; 0-7.2% antimony; 0-1.7% bismuth; and0.001-0.05% lead. Still a further and/or alterative formulation of thecorrosion resistant tin alloy includes 95-99.9% tin; 0-0.1% aluminum;0-1% antimony; 0-0.5% bismuth; 0-0.5% copper; 0-0.1% iron; 0-0.5% lead;0-0.1% nickel; and 0-0.2% zinc. Still yet a further and/or alterativeformulation of the corrosion resistant tin alloy includes 98-99.9% tin;0-0.4% antimony; 0-0.2% bismuth; 0-0.1% copper; 0-0.01% iron; 0-0.05%lead; 0-0.01% nickel; and 0-0.05% zinc. Another and/or alterativeformulation of the corrosion resistant tin alloy includes 75-99.99% tin;0-5% aluminum; 0-7.5% antimony; 0-1.7% bismuth; 0-5% copper; 0-10% lead;0-5% nickel; 0-0.5% titanium; and 0-9% zinc. Still another and/oralterative formulation of the corrosion resistant tin alloy includes98-99% tin; 0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001%arsenic; 0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01%chromium; 0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium;0-0.001% manganese; 0-0.001% molybdenum; 0-0.1% nickel; 0-0.001%silicon; 0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05%titanium; 0-0.001% vanadium; and 0-1% zinc. Yet another and/oralterative formulation of the corrosion resistant tin alloy includes50-99.999% tin; 0-7.5% aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1%boron; 0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5%copper; 0-1% iron; 0-10% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-5% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05%tellurium; 0-0.5% titanium; 0-0.1% vanadium; and 0-9% zinc. Yet anotherand/or alterative formulation of the corrosion resistant tin alloyincludes 90-99.999% tin; 0-7.5% aluminum; 0-2% antimony; 0-0.05%arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1%chromium; 0-5% copper; 0-1% iron; 0-10% lead; 0-1% magnesium; 0-0.1%manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5% silicon; 0-0.1%silver; 0-0.05% tellurium; 0-0.5% titanium; 0-0.1% vanadium; and 0-9%zinc. Still another and/or alterative formulation of the corrosionresistant tin alloy includes 75-99.999% tin; 0-7.5% aluminum; 0-2%antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium;0-1% carbon; 0-1% chromium; 0-5% copper; 0-1% iron; 0-10% lead; 0-1%magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5%silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5% titanium; 0-0.1%vanadium; and 0-10% zinc. Yet another and/or alterative formulation ofthe corrosion resistant tin alloy includes 75-99.999% tin; 0-7.5%aluminum; 0.001-5% antimony, bismuth, cadmium and/or copper; 0-2% lead;0-1% nickel; and 0-10% zinc. Still yet another and/or alterativeformulation of the corrosion resistant tin alloy includes 95-99.999%tin; 0-2% aluminum; 0.001-2% antimony, bismuth, cadmium and/or copper;0-1% lead; 0-1% nickel; and 0-2% zinc. Still another and/or alterativeformulation of the corrosion resistant tin alloy includes 98-99% tin;0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic;0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01% chromium;0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium; 0-0.001%manganese; 0-0.001% molybdenum; 0-0.9% nickel; 0-0.001% silicon;0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium;0-0.001% vanadium; and 0-1% zinc.

[0212] A general formulation of the corrosion resistant tin and zincalloy by weight percent includes the following: Tin 15-90 Zinc 10-85Antimony  0-7.5 Bismuth  0-5 Copper  0-5

[0213] One more specific formulation of the corrosion resistant tin andzinc alloy by weight percent includes the following: Tin 15-90 Zinc10-85 Aluminum  0-5 Antimony  0-7.5 Bismuth  0-5 Cadmium  0-1 Copper 0-5 Nickel  0-5

[0214] Another and/or alterative specific formulation of the corrosionresistant tin and zinc alloy by weight percent includes the following:Tin 20-80 Zinc 20-80 Aluminum  0-2 Antimony  0-1 Arsenic  0-0.05 Bismuth 0-1 Boron  0-0.1 Cadmium  0-0.1 Carbon  0-0.5 Chromium  0-0.5 Copper 0-2 Iron  0-1 Lead  0-1 Magnesium  0-1 Manganese  0-0.1 Molybdenum 0-0.1 Nickel  0-1 Silicon  0-0.5 Silver  0-0.1 Tellurium  0-0.05Titanium  0-0.5 Vanadium  0-0.1

[0215] Still another and/or alterative specific formulation of thecorrosion resistant tin and zinc alloy by weight percent includes thefollowing: Tin 30-85 Zinc 15-70 Aluminum  0-1 Antimony  0-1 Arsenic 0-0.01 Bismuth  0-1 Boron  0-0.1 Cadmium  0-0.1 Carbon  0-0.5 Chromium 0-0.1 Copper  0-1 Iron  0-0.1 Lead  0-0.1 Magnesium  0-1 Manganese 0-0.01 Molybdenum  0-0.1 Nickel  0-0.1 Silicon  0-0.5 Silver  0-0.01Tellurium  0-0.05 Titanium  0-0.05 Vanadium  0-0.1

[0216] Yet another and/or alterative specific formulation of thecorrosion-resistant tin and zinc alloy by weight percent includes thefollowing: Tin   70-90 Zinc   10-30 Aluminum 0.001-0.01 Antimony0.001-0.8 Copper 0.001-0.02 Bismuth 0.001-0.005 Boron    0-0.05 Silver   0-0.005 Carbon    0-0.05 Chromium    0-0.05 Iron    0-0.005 Magnesium   0-0.05 Manganese    0-0.01 Molybdenum    0-0.05 Silicon    0-0.05Tellurium    0-0.01 Titanium    0-0.05 Vanadium    0-0.05 Arsernc   0-0.005 Cadmium    0-0.01 Nickel    0-0.005 Lead  0.01-0.1

[0217] Still yet another and/or alterative specific formulation of thecorrosion-resistant tin and zinc alloy by weight percent includes thefollowing: Tin  79.5-81.5 Zinc  18.5-20.5 Aluminum 0.002-0.008 Antimony 0.6-0.7 Arsenic    0-0.001 Bismuth 0.002-0.005 Cadmium    0-0.001Copper 0.005-0.02 Iron    0-0.001 Lead  0.02-0.08 Nickel    0-0.001Silver    0-0.001

[0218] Examples of the tin and zinc alloy composition by weight percentinclude: Ingredients A B C D E F G H Zinc 10 15 20 25 30 35 40 45 Tin 9085 80 75 70 65 60 55 Aluminum ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5Antimony ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Bismuth ≦0.5 ≦0.5 ≦0.5≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Copper ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5Lead ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 Ingredients I J K L M N O PZinc 50 55 60 65 70 75 80 85 Tin 50 45 40 35 30 25 20 15 Aluminum ≦0.5≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Antimony ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5≦0.5 ≦0.5 ≦0.5 Bismuth ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Copper≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Lead ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1≦0.1 ≦0.1 ≦0.1

[0219] One formulation of the corrosion resistant tin and zinc alloyincludes by weight percent 20-80% tin; 20-80% zinc; 0-1% aluminum; 0-2%antimony; 0-0.02% arsenic; 0-1.5% bismuth; 0-0.1% boron; 0-0.1% cadmium;0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron; 0-1% lead;0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel;0-0.5% silicon; 0-0.05% silver; 0-0.02% sulfur; 0-0.04% tellurium;0-0.15% titanium; and 0-0.05% vanadium. Another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes30-70% tin; 30-70% zinc; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005%arsenic; 0-0.5% bismuth; 0-0.05% boron; 0-0.05% cadmium; 0-0.1% carbon;0-0.1% chromium; 0-1% copper; 0-0.6% iron; 0-0.5% lead; 0-0.1%magnesium; 0-0.1% manganese; 0-0.05% molybdenum; 0-0.9% nickel; 0-0.01%silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1%titanium; and 0-0.01% vanadium; and the tin plus zinc content is atleast 90 weight percent of the alloy. Still another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes40-60% tin; 40-60% zinc; 0-0.4% aluminum; 0-1% antimony and/or bismuth;0-0.001% arsenic; 0-0.01% boron; 0-0.005% cadmium; 0-0.05% carbon;0-0.05% chromium; 0-0.1% copper; 0-0.05% iron; 0-0.1% lead; 0-0.01%magnesium; 0-0.01% manganese; 0-0.01% molybdenum; 0-0.9% nickel;0-0.001% silicon; 0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium;0-0.05% titanium; and 0-0.001% vanadium; and the tin plus zinc contentis at least 95 weight percent of the alloy. Yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 45-55% zinc; 45-55% tin; 0-0.4% aluminum; 0-0.8% antimonyand/or bismuth; 0-0.001% arsenic; 0-0.001% boron; 0-0.001% cadmium;0-0.01% carbon; 0-0.05% copper; 0-0.001 iron; 0-0.08% lead; 0-0.001%magnesium; 0-0.001% manganese; 0-0.001% molybdenum; 0-0.9% nickel;0-0.001% silicon; 0-0.005% silver; 0-0.001% sulfur; 0-0.001% tellurium;0-0.05% titanium and 0-0.001% vanadium; and the tin content plus thezinc content is at least 99% of the alloy. Still yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 30-85% tin; 15-70% zinc; 0-0.5% aluminum; 0-2% antimony;0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.1%carbon; 0-0.1% chromium; 0-2% copper; 0-1% iron; 0-0.5% lead; 0-0.4%magnesium; 0-0.1% manganese; 0-0.05% molybdenum; 0-1% nickel; 0-0.5%silicon; 0-0.05% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.15%titanium; and 0-0.05% vanadium. A further and/or alternative formulationof the corrosion resistant tin and zinc alloy includes 30-65% tin;35-70% zinc; 0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.05%arsenic; 0-0.01% cadmium; 0-0.5% copper; less than 0.05% iron; less than0.1% lead; 0-0.1% magnesium; 0-0.1% manganese; 0-0.5% nickel; 0-0.05%silver; 0-0.05% titanium; and the tin plus zinc content is at least 98%of the metal alloy. Still a further and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 40-60% tin; 40-60%zinc; 0-0.4% aluminum; 0-0.8% antimony and/or bismuth; 0-0.005% arsenic;0-0.005% cadmium; 0-0.2% copper; 0-0.05% iron; 0-0.1% lead; 0-0.001%magnesium; 0-0.001% manganese; 0-0.05% nickel; 0-0.005% silver; 0-0.05%titanium; and the tin plus zinc content is at least 99% of the metalalloy. Yet a further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 60-90% tin; 10-40% zinc; 0-0.5%aluminum; 0-2% antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron;0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; up to 1%iron; less than 0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.01% silver; 0-0.01% sulfur;0-0.01% tellurium; 0-0.15% titanium; and 0-0.1% vanadium. Still yet afurther and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 70-90% tin; 10-30% zinc; 0-0.1% aluminum; 0-1%antimony and/or bismuth; 0-0.05% arsenic; 0-0.01% cadmium; 0-0.5%copper; less than 0.05% iron; less than 0.1% lead; 0-0.1% magnesium;0-0.1% manganese; 0-0.5% nickel; 0-0.05% silver; 0-0.05% titanium; andthe tin plus zinc content is at least 95% of the metal alloy. Yet afurther and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 75-85% tin; 15-25% zinc; 0.001-0.01% aluminum;0.001-0.8% antimony and/or bismuth; 0-0.005% arsenic; 0-0.001% cadmium;0.005-0.02% copper; 0-0.001 iron; 0.01-0.08% lead; 0-0.001% magnesium;0-0.001% manganese; 0-0.001% nickel; 0-0.01 silver; 0-0.001% titanium;and the tin plus zinc content is at least 98% of the metal alloycoating. Another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 15-35% tin; 65-85% zinc; 0-7.5%antimony; 0-1.7% bismuth. Yet another and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 15-35% tin; 65-85%zinc; and 0.01-0.5% antimony and/or bismuth. Still another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 15-35% tin; 65-85% zinc; 0.01-0.5% antimony and/or bismuth; andless than 2% copper and/or iron. Still yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes15-35% tin; 65-85% zinc; 0-0.5% antimony; 0-0.5% bismuth; and less than0.01% lead. A further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 15-35% tin; 65-85% zinc; 0-0.5%antimony; 0-0.5% bismuth; less than 2% copper and/or iron; and less than0.01% lead. Yet a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 15-35% tin; 65-85% zinc;0-7.5% antimony; 0-1.7% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05%lead. Another and/or alternative formulation of the corrosion resistanttin and zinc alloy includes 70-90% tin; 10-30% zinc; 0-7.5% antimony;0-1.7% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Stillanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 80-90% tin; 10-20% zinc; 0-7.5% antimony; 0-1.7%bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 70-90% tin; 10-30% zinc; 0-2.5% antimony; 0-0.5% bismuth; 0-2%copper; 0-0.1% iron; and 0-0.05% lead. Still yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 70-90% tin; 10-30% zinc; 0.5-7.5% antimony; 0.5-1.7% bismuth;0-2% copper; 0-0.1% iron; and 0-0.05% lead. A further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes80-90% tin; 10-20% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-2% copper;0-0.1% iron; and 0-0.01% lead. A further and/or alternative formulationof the corrosion resistant tin and zinc alloy includes 15-70% tin;30-85% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-5% copper; 0-0.1% iron;0-0.05% lead; and 0-5% nickel. Yet a further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes15-70% tin; 30-85% zinc; 0-0.5% antimony; 0-0.5% bismuth; 0-2% copper;0-0.1% iron; 0-0.01% lead; and 0-1% nickel. Still a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 35-70% tin; 30-65% zinc; 0-0.5% antimony; 0-0.5% bismuth; 0-2%copper; 0-0.1% iron; 0-0.05% lead; and 0-1% nickel. Still yet a furtherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 45-55% tin; 45-55% zinc; 0-0.5% antimony and/or bismuth;1-1.5% copper; 0-0.1% iron; 0-0.01% lead; 0.3-0.9% nickel; and the tincontent plus zinc content at least 95% of the metal alloy. Anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 20-90% tin; 10-80% zinc; 0-0.5% aluminum; 0-1% antimony;0-2.7% copper; and 0-0.15% titanium. Still another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-90% tin; 10-80% zinc; 0-0.3% aluminum; 0-5.5% antimony; and 0-1%copper. Yet another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 20-90% tin; 10-80% zinc; 0-5%aluminum; 0-5.5% antimony; 0-1.7% bismuth; 0-5% copper; 0-0.1% iron;0-0.05% lead; 0-5% magnesium; 0-5% nickel; and 0-1% titanium. Stillanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 20-75% tin; 25-80% zinc; 0-1% aluminum; 0-5.5%antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.1% iron; 0-0.05% lead; 0-1%magnesium; 0-1% nickel; and 0-0.5% titanium Still yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 20-80% tin; 20-80% zinc; 0-0.5% aluminum; 0-5.5% antimony;0-1.5% bismuth; 0-2.7% copper; 0-0.1% iron; 0-0.01% lead; 0-0.4%magnesium; 0-1% nickel; and 0-0.15% titanium. A further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 35-70% tin; 30-65% zinc; 0-0.3% aluminum; 0.05-1% antimonyand/or bismuth; 0-1% copper; 0-0.1% iron; 0-0.01% lead; 0-0.4%magnesium; 0-0.7% nickel; 0-0.15% titanium; and the tin plus zinccontent is at least 90% of the metal alloy. Yet a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 15-90% tin; 10-85% zinc; 0-5% aluminum; 0-7.5% antimony; 0-1.7%bismuth; 0-5% copper; 0-1% iron; 0-1% lead; 0-5% magnesium; 0-5% nickel;and 0-1% titanium. Still yet a further and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 10-70% tin; 30-90%zinc; 0-0.25% aluminum; 0-0.02% chromium; 0-1.5% copper; 0-0.01% iron;0-0.01% lead; 0-0.01% magnesium; and 0-0.18% titanium. Another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 10-70% tin; 30-90% zinc; 0-0.25% aluminum; 0-0.02% chromium;0-1.5% copper; 0-0.01% iron; 0-0.01% lead; 0-0.01% magnesium; and0-0.18% titanium. Still another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 15-90% tin; 10-85% zinc;0-0.01% aluminum; 0-1% antimony; 0-0.005% arsenic; 0-0.01% bismuth;0-0.05% cadmium; 0-0.05% copper; 0-0.005% iron; 0-0.1% lead; 0-0.005%nickel; and 0-0.005% silver. Yet another and/or alternative formulationof the corrosion resistant tin and zinc alloy includes 70-90% tin;10-30% zinc; 0-0.01% aluminum; 0.001-0.8% antimony; 0-0.005% arsenic;0.001-0.005% bismuth; 0-0.01% cadmium; 0-0.02% copper; 0-0.005% iron;0-0.1% lead; 0-0.005% nickel; and 0-0.005% silver. Still yet anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 79.5-81.5% tin; 18.5-20.5% zinc; 0.002-0.008% aluminum;0.6-0.7% antimony; 0-0.001% arsenic; 0.002-0.005% bismuth; 0-0.001%cadmium; 0.005-0.02% copper; 0-0.001% iron; 0.02-0.08% lead; 0-0.001%nickel; and 0-0.001% silver. A further and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 70-90% tin; 10-30%zinc; 0-0.01% aluminum; 0-1% antimony; 0-0.005% arsenic; 0-0.01%bismuth; 0-0.01% cadmium; 0-0.5% copper; 0-0.005% iron; 0-0.1% lead;0-0.005% nickel; and 0-0.005% silver. Yet further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes60-90% tin; 10-40% zinc; 0-0.5% aluminum; 0-2% antimony; 0-0.01%arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.5% carbon;0.0-0.5% chromium; 0-2% copper; up to 1% iron; less than 0.5% lead;0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel;0-0.5% silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium;0-0.15% titanium; and 0-0.1% vanadium. Still a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 70-90% tin; 10-30% zinc; 0-0.1% aluminum; 0-1% antimony and/orbismuth; 0-0.05% arsenic; 0-0.01% cadmium; 0-0.5% copper; less than0.05% iron; less than 0.1% lead; 0-0.1% magnesium; 0-0.1% manganese;0-0.5% nickel; 0-0.5% silicon; 0-0.05% silver; 0-0.05% titanium; and thetin plus zinc content is at least 95% of the metal alloy. Still yet afurther and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 75-85% tin; 15-25% zinc; 0.001-0.01% aluminum;0.001-0.8% antimony and/or bismuth; 0-0.005% arsenic; 0-0.001% cadmium;0.005-0.02% copper; 0-0.0015% iron; 0.01-0.08% lead; 0-0.001% magnesium;0-0.001% manganese; 0-0.001% nickel; 0-0.5% silicon; 0-0.01% silver;0-0.001% titanium; and the tin plus zinc content is at least 98% of themetal alloy. Another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 15-90% tin; 10-85% zinc; 0-2%aluminum; 0-2% antimony; 0-1.7% bismuth; 0-2% copper; 0-1% iron; 0-0.5%lead; 0-2% magnesium; 0-2% nickel; and 0-1% titanium. Still anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 15-90% tin; 10-85% zinc; 0-1% aluminum; 0-2% antimony;0-1.7% bismuth; 0-2% copper; 0-1% iron; 0-0.5% lead; 0-1% magnesium;0-1% nickel; and 0-0.5% titanium. Yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-90% tin; 10-80% zinc; 0-0.51% aluminum; 0-2% antimony; 0-1.5%bismuth; 0-0.01% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium;0-2% copper; 0-1% iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese;0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon; and 0-0.15% titanium;and 0-0.1% vanadium. Still another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 20-65% tin; 30-80% zinc;0-0.3% aluminum; 0-1% antimony and/or bismuth; 0-1% copper; 0-0.6% iron;0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.7% nickel; 0-0.15%titanium; and the tin plus zinc content is at least 95% of the metalalloy. Still yet another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 20-50% tin; 50-80% zinc; 0-0.3%aluminum; 0.005-0.5% antimony and/or bismuth; 0-0.05% cadmium; 0-0.2%copper; 0-0.6% iron; 0-0.4% lead; 0-0.1% magnesium; 0-0.05% manganese;0-0.1% nickel; 0-0.1% silicon; 0-0.15% titanium; and the tin plus zinccontent is at least 95% of the metal alloy. A further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-70% tin; 30-75% zinc; 0.0005-2% aluminum; 0.001-2% antimony;0.0001-1% bismuth; 0-2% copper; 0-0.5% lead; and 0.0001-0.1% titanium.Yet a further and/or alternative formulation of the corrosion resistanttin and zinc alloy includes 40-60% tin; 40-60% zinc; 0.0005-0.75%aluminum; 0.001-1% antimony; O-0.01% arsenic; 0.0001-0.2% bismuth;0-0.01% cadmium; 0.001-1% copper; 0-0.01% chromium; 0-0.1% iron; 0-0.1%lead; 0-0.01% manganese; 0-0.2% nickel; 0-0.01% silver; and 0.0005-0.05%titanium. Still yet a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 25-70% tin; 30-75% zinc;0-0.5% aluminum; 0-0.5% copper; 0-0.1% lead; and 0-0.05% titanium.Another and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 30-70% tin; 30-70% zinc; 0.0001-0.5% aluminum;0.001-2% antimony; 0-0.01% arsenic; 0.0001-1% bismuth; 0-0.01% boron;0-0.01% cadmium; 0-0.05% carbon; 0-0.05% chromium; 0-2% copper; 0-0.1%iron; 0-0.5% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.01%molybdenum; 0-1% nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01%sulfur; 0-0.01% tellurium; 0.0001-0.1% titanium; and 0-0.01% vanadium.Still another and/or alternative formulation of the corrosion resistanttin and zinc alloy includes 40-60% tin; 40-60% zinc; 0.0005-0.4%aluminum; 0.01-0.8% antimony; 0-0.005% arsenic; 0.001-0.05% bismuth;0-0.005% cadmium; 0.005-0.5% copper; 0-0.05% iron; 0-0.1% lead; 0-0.05%nickel; 0-0.005% silver; and 0.0005-0.05% titanium. Yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 48-52% tin; 48-52% zinc; 0.005-0.24% aluminum; 0.05-0.64%antimony; 0-0.001% arsenic; 0.002-0.005% bismuth; 0-0.001% cadmium;0.01-0.3% copper; 0-0.016% iron; 0-0.08% lead; 0-0.001% nickel; 0-0.001silver; and 0.001-0.02% titanium. Yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes15-90% tin; 10-85% zinc; 0-5% aluminum; 0-5% antimony; 0-5% bismuth;0-1% cadmium; 0-5% copper; 0-1% iron; 0-1% lead; and 0-1% nickel. Stillanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 30-85% tin; 15-70% zinc; 0-1% antimony; 0-0.1%arsenic; 0-1% bismuth; 0-0.1% cadmium; 0-1% copper; 0-0.1% iron; 0-0.1%lead; 0-0.1% manganese; 0-0.1% nickel; 0-0.1% silver; and 0-0.05%titanium. Still yet another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 30-80% tin; 20-70% zinc;0-0.5% aluminum; 0-0.5% antimony; 0-0.5% bismuth; 0-0.5% copper; and0-0.1% lead. A further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 30-85% tin; 15-70% zinc; 0-0.5%aluminum; 0-2 antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron;0-0.1% cadmium; 0-0.1% carbon; 0-0.1% chromium; 0-2% copper; 0-1% iron;0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.05% molybdenum;0-1% nickel; 0-0.5% silicon; 0-0.05% silver; 0-0.01% tellurium; 0-0.15%titanium; and 0-0.05% vanadium. Yet a further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes30-65% tin; 35-70% zinc; 0-0.1% aluminum; 0-1% antimony and/or bismuth;0-0.05% arsenic; 0-0.01% cadmium; 0-0.5% copper; 0-0.05% iron; 0-0.1%lead; 0-0.1% magnesium; 0-0.1% manganese; 0-0.5% nickel; 0-0.05% silver;0-0.05% titanium; and the tin plus zinc content is at least 98% of themetal alloy. Still yet a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 40-60% tin; 40-60% zinc;0-0.4% aluminum; 0-0.8% antimony and/or bismuth; 0-0.005% arsenic;0-0.005% cadmium; 0-0.2% copper; 0-0.001% iron; 0.01-0.08% lead;0-0.001% magnesium; 0-0.001% manganese; 0-0.05% nickel; 0-0.005% silver;0-0.05% titanium; and the tin plus zinc content is at least 99% of themetal alloy. Another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 15-90% tin; 10-85% zinc; 0-5%aluminum; 0-7.5% antimony; 0-5% bismuth; 0-1% cadmium; 0-5% copper; 0-5%nickel; and 0-0.5% titanium. Still another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-80% tin; 20-80% zinc; 0-2% aluminum; 0-1% antimony; 0-0.05% arsenic;0-1% bismuth; 0-0.1% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5%chromium; 0-2% copper; 0-1% iron; 0-1% lead; 0-1% magnesium; 0-0.1%manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.1%silver; 0-0.05% tellurium; 0-0.5% titanium; and 0-0.1% vanadium. Yetanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 20-80% tin; 20-80% zinc; 0-1% aluminum; 0-2%antimony; 0-0.02% arsenic; 0-1.5% bismuth; 0-0.5% boron; 0-0.1% cadmium;0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron; 0-1% lead;0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel;0-0.05% silicon; 0-0.05% silver; 0-0.02% sulfur; 0-0.04% tellurium;0-0.15% titanium; and 0-0.05% vanadium. Still yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 30-70% tin; 30-70% zinc; 0-0.4% aluminum; 0-0.8% antimony;0-0.005% arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium; 0-0.1%carbon; 0-0.1% chromium; 0-1% copper; 0-0.6% iron; 0-0.5% lead; 0-0.1%magnesium; 0-0.1% manganese; 0-0.05% molybdenum; 0-0.7% nickel; 0-0.01%silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1%titanium; 0-0.01% vanadium; and the tin plus zinc content is at least 90weight percent of the metal alloy. A and/or alternative furtherformulation of the corrosion resistant tin and zinc alloy includes40-60% tin; 40-60% zinc; 0-0.4% aluminum; 0-1% antimony and/or bismuth;0-0.001% arsenic; 0-0.01% boron; 0-0.005% cadmium; 0-0.05% carbon;0-0.05% chromium; 0-0.1% copper; 0-0.05% iron; 0-0.1% lead; 0-0.01%magnesium; 0-0.01% manganese; 0-0.01% molybdenum; 0-0.3% nickel;0-0.001% silicon; 0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium;0-0.05% titanium; 0-0.001% vanadium; and the tin plus zinc content is atleast 95 weight percent of the metal alloy. Yet a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 45-55% zinc; 45-55% tin; 0-0.4% aluminum; 0-0.8% antimonyand/or bismuth; 0-0.001% arsenic; 0-0.001% boron; 0-0.001% cadmium;0-0.01% carbon; 0-0.05% copper; 0-0.001 iron; 0-0.08% lead; 0-0.001%magnesium; 0-0.001% manganese; 0-0.001% molybdenum; 0-0.1% nickel;0-0.001% silicon; 0-0.005% silver; 0-0.001% sulfur; 0-0.001% tellurium;0-0.05% titanium; 0-0.001% vanadium; and the tin content plus the zinccontent is at least 99% of the metal alloy. Another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-80% tin; 20-80% zinc; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic;0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5%chromium; 0-2% copper; 0-1% iron; 0-1% lead; 0-0.4% magnesium; 0-0.1%manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.05%silver; 0-0.02% sulfur; 0-0.04% tellurium; 0-0.15% titanium; and 0-0.05%vanadium. Yet another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 30-70% tin; 30-70% zinc; 0-0.4%aluminum; 0-0.8% antimony; 0-0.005% arsenic; 0-0.5% bismuth; 0-0.1%boron; 0-0.05% cadmium; 0-0.1% carbon; 0-0.1% chromium; 0-1% copper;0-0.6% iron; 0-0.5% lead; 0-0.1% magnesium; 0-0.1% manganese; 0-0.05%molybdenum; 0-0.9% nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01%sulfur; 0-0.01% tellurium; 0-0.1% titanium; 0-0.01% vanadium; and thetin plus zinc content is at least 90 weight percent of the metal alloy.Still another and/or alternative formulation of the corrosion resistanttin and zinc alloy includes 40-60% tin; 40-60% zinc; 0-0.4% aluminum;0-1% antimony and/or bismuth; 0-0.001% arsenic; 0-0.01% boron; 0-0.005%cadmium; 0-0.05% carbon; 0-0.05% chromium; 0-0.1% copper; 0-0.05% iron;0-0.1% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.01% molybdenum;0-0.9% nickel; 0-0.001% silicon; 0-0.001% silver; 0-0.001% sulfur;0-0.001% tellurium; 0-0.05% titanium; 0-0.001% vanadium; and the tinplus zinc content is at least 95 weight percent of the metal alloy.Still yet another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 45-55% zinc; 45-55% tin; 0-0.4%aluminum; 0-0.8% antimony and/or bismuth; 0-0.001% arsenic; 0-0.001%boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.05% copper; 0-0.001% iron;0-0.08% lead; 0-0.001% magnesium; 0-0.001% manganese; 0-0.001%molybdenum; 0-0.9% nickel; 0-0.001% silicon; 0-0.005% silver; 0-0.001%sulfur; 0-0.001% tellurium; 0-0.05% titanium; 0-0.001% vanadium; and thetin content plus the zinc content is at least 99% of the metal alloy. Afurther and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 15-90% tin; 10-85% zinc; 0-0.5% aluminum; 0-5.5%antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.4% magnesium; 0-1% nickel;0-0.15% titanium. Yet a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 15-90% tin; 10-85% zinc;0-0.3% aluminum; 0-1% antimony; 0-1.7% bismuth; 0-1% copper; 0-0.4%magnesium; 0-1% nickel; 0-0.15% titanium. Still a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 15-80% tin; 20-85% zinc; 0-0.3% aluminum; 0-1% antimony; 0-1.7%bismuth; 0-1% copper; 0-0.4% magnesium; 0-1% nickel; 0-0.15% titanium.Still yet further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 15-80% tin; 20-85% zinc; 0-0.5%aluminum; 0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.4%magnesium; 0-1% nickel; and 0-0.15% titanium. Another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes15-70% tin; 30-85% zinc; 0-0.25% aluminum; 0-1.5% copper; 0-0.02%chromium; 0-0.01% iron; 0-0.01% lead; 0-0.01% manganese; and 0-0.18%titanium. Still another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 49.75-50.25% tin; 49.75-50.25%zinc; 0-0.02% aluminum; 0-0.2% antimony; 0-0.2% arsenic; 0-0.2% copper;0-0.025% iron; 0-0.002% palladium; and 0-0.015% titanium. Yet anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 49.5-50.5% tin; 49.5-50.5% zinc; 0.005-0.21% aluminum;0.05-0.64% antimony; 0-0.001% arsenic; 0-0.004% bismuth; 0-0.001%cadmium; 0.01-0.3% copper; 0-0.001% iron; 0-0.001% nickel; 0-0.001%silver; 0.001-0.02% titanium. Still yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes49.75-50.25% tin; 49.75-50.25% zinc; 0-0.25% aluminum; 0-0.35% antimony;0-0.02% arsenic; 0-0.001% cadmium; 0-0.02% copper; 0-0.025% iron;0-0.08% lead; and 0-0.0175% titanium. A further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes35-70% tin; 30-65% zinc; 0-5% copper; and 0-5% nickel. Yet a furtherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 20-80% tin; 20-85% zinc; 0-0.1% lead. Still a furtherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 15-30% tin; 70-85% zinc; and 0-0.1% lead. Yet a furtherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 15-90% tin; 10-85% zinc; and 0-2% magnesium. Still yet afurther and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 10-75% tin; 25-90% zinc; 0-0.25% aluminum;0-1.5% copper; 0-0.02% chromium; 0-0.01% iron; 0-0.01% lead; 0-0.01%manganese; and 0-0.18% titanium. Another and/or alternative formulationof the corrosion resistant tin and zinc alloy includes 15-35% tin;65-85% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-0.1% iron; and 0-0.05%lead. Yet another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 15-70% tin; 30-85% zinc; 0-7.5%antimony; 0-1.7% bismuth; 0-5% copper; 0-0.1% iron; 0-0.05% lead; and0.3-5% nickel. Still another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 15-70% tin; 30-85% zinc;0-7.5% antimony; 0-1.7% bismuth; 0-2% copper; 0-0.1% iron; 0-0.05% lead;and 0.3-1% nickel. Still yet another and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 15-70% tin; 30-85%zinc; 0.1-5% copper; and 0.3-5% nickel. A further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes35-70% tin; 30-65% zinc; 0.1-2% copper; and 0.3-1% nickel. Still afurther and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 35-70% tin; 30-65% zinc; 0.1-1.5% copper; and0.3-0.9% nickel. A further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes at least 15% tin; zinc;and at least 0.05% antimony, bismuth and/or copper. Still a furtherformulation of the corrosion resistant tin and zinc alloy includes10-20% zinc; 0-2.5% antimony; 0-0.5% bismuth; and the remainder tin.Still a further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 80-90% tin; 10-20% zinc; 0.5-1.7%bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Still yet a furtherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 80-90% tin; 10-20% zinc; 0.5-7.5% antimony; 0-2% copper;0-0.1% iron; and 0-0.05% lead. Another and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 80-90% tin; 10-20%zinc; 0-0.5% antimony; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Stillanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 80-90% tin; 10-20% zinc; 0-0.5% bismuth; 0-2%copper; 0-0.1% iron; and 0-0.05% lead. Yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes70-90% tin; 10-30% zinc; at least 0.01% antimony. Still yet anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 70-90% tin; 10-30% zinc; 0.01-1.7% bismuth. Still anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 70-90% tin; 10-30% zinc; 0.1-2% iron. Yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 70-90% tin; 10-30% zinc; 0.1-2% copper. Still yet anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes a majority of tin and zinc, 0-0.5% aluminum; 0-5.5%antimony; 0-2.7% copper; and 0-0.15% titanium. A further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes a majority of tin and zinc, 0-0.3% aluminum; 0-1% antimony; and0-1% copper. Yet a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 20-90% tin; 10-80% zinc;0-1% aluminum; 0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.1%iron; 0-0.05% lead; 0-1% magnesium; 0-1% nickel; and 0-0.5% titanium.Still a further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 20-80% tin; 20-80% zinc; 0-5%aluminum; 0-5.5% antimony; 0-1.5% bismuth; 0-5% copper; 0-5% magnesium;0-5% nickel; and 0-1% titanium. Still yet a further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-80% tin; 20-80% zinc; 0-0.5% aluminum; 0-5.5% antimony; 0-1.7%bismuth; 0-2.7% copper; 0-0.4% magnesium; 0-1% nickel; and 0-0.15%titanium. Still a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 20-80% tin; 20-80% zinc;0-0.3% aluminum; 0-1% antimony; 0-1.7% bismuth; 0-1% copper; 0-0.4%magnesium; 0-0.7% nickel; and 0-0.15% titanium. Another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes a majority of tin and zinc, 0-0.5% aluminum; 0-2% antimony;0-2% copper; and 0-0.15% titanium. Still another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes amajority of tin and zinc, 0-0.3% aluminum; 0-1% antimony; and 0-1%copper. Yet another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 20-90% tin; 10-80% zinc; 0-2%aluminum; 0-2% antimony and/or bismuth; 0-2% copper; 0-1% iron; 0-0.5%lead; 0-0.4% magnesium; 0-0.1% manganese; 0-1% nickel; and 0-0.15%titanium. Still yet another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 20-65% tin; 35-80% zinc;0-2% aluminum; 0-1% antimony and/or bismuth; 0-1% copper; 0-0.6% iron;0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.7% nickel; and0-0.15% titanium. Yet another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 20-50% tin; 50-80% zinc;0-0.3% aluminum; 0.005-0.5% antimony and/or bismuth; 0-0.2% copper;0-0.6% iron; 0-0.4% lead; 0-0.4% magnesium; 0-0.05% manganese; 0-0.1%nickel; and 0-0.15% titanium. A further and/or alternative formulationof the corrosion resistant tin and zinc alloy includes 15-90% tin;10-85% zinc; 0-2% aluminum; 0-2% antimony; 0-1.7% bismuth; 0-2% copper;0-1% iron; 0-1% lead; 0-2% magnesium; 0-2% nickel; and 0-1% titanium.Still a further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 30-85% tin; 15-70% zinc; 0-1%aluminum; 0-1% antimony; 0-0.01% arsenic; 0-1% bismuth; 0-0.1% cadmium;0-0.1% chromium; 0-1% copper; 0-0.1% iron; 0-0.1% lead; 0-0.01%manganese; 0-0.1% nickel; 0-0.01% silver; and 0-0.05% titanium. Stillyet a further and/or alternative formulation of the corrosion resistanttin and zinc alloy includes 50-85% tin; 15-50% zinc; 0-7.5% aluminum;0-2% antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5%cadmium; 0-1% carbon; 0-1% chromium; 0-5% copper; 0-1% iron; 0-10% lead;0-1% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5%silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5% titanium; and 0-0.1%vanadium. Yet a further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 15-50% tin; 50-85% zinc; 0-7.5%aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth;0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5% copper; 0-1% iron;0-10% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-5%nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5%titanium; and 0-0.1% vanadium. Still a further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-80% tin; 20-80% zinc; 0-5% aluminum; 0-7.5% antimony; 0-5% bismuth;0-1% cadmium; 0-5% copper; 0-5% nickel; and 0-0.5% titanium. Still yet afurther and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 15-90% tin; 10-85% zinc; 0-7.5% aluminum; 0-2%antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium;0-1% carbon; 0-1% chromium; 0-5% copper; 0-1% iron; 0-10% lead; 0-1%magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5%silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5% titanium; and 0-0.1%vanadium. Another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 30-70% tin; 30-70% zinc; 0-7.5%aluminum; 0-2% antimony; 0-1.7% bismuth; 0-0.5% cadmium; 0-5% copper;0-10% lead; and 0-5% nickel. Still another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes40-60% tin; 40-60% zinc; 0-2% aluminum; 0-2% antimony, bismuth, cadmiumand/or copper; 0-2% lead; and 0-1% nickel.

[0220] The following are several examples of tin or tin and zinc alloybeing applied by various processes to various types of metal strip. Thefollowing examples also illustrate various ways the coated metal stripcan be formed in various types of products. The following examplesfurther illustrate the formation of the metal alloy into various typesof materials. The following examples only illustrate a few, not all,aspects of the present invention.

EXAMPLE A

[0221] A metal strip is unwound from a roll of metal strip. The metalstrip has a thickness of less than about 762 microns. The metal strip iscontinuously passed through an electrolytic tank to plate nickel on thestrip surface. The nickel plated layer has a thickness of about 1-3microns. The metal alloy includes at least about 85% tin and at leastabout 10% zinc and less than about 0.5% lead. The metal alloy in themelting pot at a temperature of about 301-455° C. The metal strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The metal strip has a resident time in themelting pot of less than about 10 seconds. The coated metal strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated metal strip is rewound intoa roll of coated metal strip.

EXAMPLE B

[0222] A metal strip is unwound from a roll of metal strip. The metalstrip has a thickness of less than about 762 microns. The metal strip isplated with chromium of a thickness of less than about 3 microns. Ametal alloy having a composition of at least about 45% tin, at leastabout 45% zinc, less than about 1% of a metal additive, and less thanabout 0.1% lead is coated onto the metal strip. The metal alloy isheated in a melting pot at a temperature of about 301-482° C. The stripis passed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The metal strip has a resident time in themelting pot of less than about 10 seconds. The coated metal strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated metal strip is rewound intoa roll of coated metal strip.

EXAMPLE C

[0223] A metal strip is unwound from a roll of metal strip. The metalstrip has a thickness of less than about 762 microns. The metal strip iscontinuously plated with a tin layer of about 1-3 microns thick. A metalalloy having a composition of at least about 45% tin and at least about45% zinc is coated onto the metal strip. The metal alloy is heated in amelting pot at a temperature of about 301-482° C. The metal strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft./min. The metal strip has a resident time in themelting pot of less than about 10 seconds. The coated metal strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated metal strip is rewound intoa roll of coated metal strip.

EXAMPLE D

[0224] A metal strip is unwound from a roll of metal strip andcontinuously plated with a tin layer of a thickness of less than about 3microns. The metal strip has a thickness of less than about 762 microns.A metal alloy having a composition of at least about 45% tin, at leastabout 45% zinc, and less than about 0.1% lead is coated onto the metalstrip. The metal alloy is heated in a melting pot at a temperature ofabout 301-427° C. The metal strip is passed through the melting pothaving a length of about 16 feet at a speed of about 100 ft/min. Themetal strip has a resident time in the melting pot of less than about 10seconds. The coated metal strip is passed through coating rollers and/oran air-knife to achieve a coating thickness of about 7-77 microns. Thecoated metal strip is rewound into a roll of coated metal strip.

EXAMPLE E

[0225] A metal strip is unwound from a roll of metal strip. The metalstrip is continuously plated with a tin layer of about 1-3 micronsthick. The metal strip has a thickness of less than about 762 microns. Ametal alloy having a composition of at least about 20% tin, and at leastabout 75% zinc and is heated in a melting pot at a temperature of about301-427° C. The metal strip is passed through the melting pot having alength of about 16 feet at a speed of about 100 ft/min. The metal striphas a resident time in the melting pot of less than about 10 seconds.The coated metal strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-77 microns. Thecoated metal strip is rewound into a roll of coated metal strip.

EXAMPLE F

[0226] A metal strip is unwound from a roll of metal strip and ispickled with a hydrochloric acid solution and a copper sulfate solution.Copper is plated onto the metal strip surface during the picklingprocess forming a copper layer of about 1-3 microns thick. The metalstrip has a thickness of less than about 762 microns. The metal alloyincludes at least about 70% tin, at least about 25% zinc, and less thanabout 0.2% lead. The metal alloy in the melting pot is heated to atemperature of about 301-482° C. The metal strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft/min. The metal strip has a resident time in the melting pot of lessthan about 10 seconds. The coated metal strip is passed through coatingrollers and/or an air-knife to achieve a coating thickness of about 7-77microns. The coated metal strip is rewound into a roll of coated metalstrip.

EXAMPLE G

[0227] A metal strip is unwound from a roll of metal strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating the metal alloy. The metalstrip has a thickness of less than about 762 microns. The metal strip isnot pre-heated prior to coating. A tin alloy having a composition ofabout 90-99% tin and less than about 2% lead is coated onto the metalstrip. The tin alloy in the melting pot is heated to at least above238-246° C. The metal strip is passed through the melting pot at a speedof about 100 ft/min. The metal strip has a resident time in the meltingpot of less than about 10 seconds. The coated metal strip is passedthrough coating rollers and/or an air knife to achieve a coatingthickness of about 7-51 microns. The coated metal strip is then cooled.The coated metal strip is then oxidized to remove the coated tin alloyand to expose and passify the heat created intermetallic layer. Themetal strip is then wound into a roll of the metal strip.

EXAMPLE H

[0228] A metal strip is unwound from a roll of metal strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The metal strip has athickness of less than about 762 microns. The metal strip is plated withnickel having a thickness of less than about 3 microns. The metal stripis preheated prior to coating. A tin alloy having a composition of above90-99% tin and less than about 2% lead is coated onto the metal strip.The metal alloy is heated in a melting pot to a temperature of about238-482° C. The metal strip is passed through the melting pot at a speedof about 100 ft/min. The metal strip has a resident time in the meltingpot of less than about 10 seconds. The coated metal strip is passedthrough coating rollers and/or an air-knife to achieve a coatingthickness of about 7-51 microns. The coated metal strip is cooled andthen oxidized to remove the tin alloy to expose and passify the heatcreated intermetallic layer. The metal strip is then wound into a rollof metal strip.

EXAMPLE I

[0229] A metal strip is unwound from a roll of metal strip. The metalstrip has a thickness of less than about 762 microns. The metal strip isnot pre-heated prior to coating with a metal alloy. A tin alloy having acomposition of about 90-99% tin, and less than about 0-5% lead is coatedonto the metal strip. The tin alloy is applied to the metal strip by anelectroplating process. The plated metal strip is then flow heated forless than about 5 minutes. The coated metal strip is then passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-51 microns. The coated metal strip is then cooled. The coatedmetal strip is then oxidized to remove the tin alloy and to expose andpassify the heat created intermetallic layer. The metal strip is thenwound into a roll of metal strip.

EXAMPLE J

[0230] A metal strip is unwound from a roll of metal strip and platedwith a zinc layer having a thickness of less than about 3 microns. Themetal strip has a thickness of less than about 762 microns. The metalstrip is pre-heated prior to coating with a metal alloy. A tin alloyhaving a composition of about 90-99% tin and less than about 0-1% leadis coated onto the metal strip. The metal strip is passed through ametal spaying process at a speed of up to about 100 ft/min to coat themetal strip. The coated metal strip is then passed through coatingrollers and/or an air-knife to achieve a coating thickness of about 7-51microns. The coated metal strip is cooled and then oxidized to removethe tin alloy and to expose and passify the heat created intermetalliclayer. The metal strip is then cut into metal sheets.

EXAMPLE K

[0231] A metal strip is unwound from a roll of metal strip and ispickled with an acid solution and then chemically activated with achemical activation solution. The metal strip is then plated with ametal layer of about 1-3 microns thick. The metal strip is notpre-heated prior to coating with a metal alloy. A tin alloy having acomposition of about 90-99% tin is coated onto the metal strip. The tinalloy is plated onto the metal strip and then flow heated. The metalstrip is then coated again by a spray metal process. The coated metalstrip is then passed through coating rollers and/or an air-knife toachieve a coating thickness of about 7-51 microns. The coated metalstrip is then cooled and wound into a roll of coated metal strip. Theroll of coated metal strip is formed into roofing materials andinstalled on a building. The formed coated metal strip is then exposedto an oxidizing solution on site to remove the tin alloy and expose andpassify the heat created intermetallic layer.

EXAMPLE L

[0232] A carbon steel strip is unwound from a roll of carbon steelstrip. The carbon steel strip has a thickness of less than about 762microns. The carbon steel strip is continuously passed through anelectrolytic tank to plate nickel on the carbon steel strip surface. Thenickel plated layer has a thickness of about 1-3 microns. A metal alloyhaving a composition of at least about 95% tin and zinc, and less thanabout 0.5% lead is coated onto the carbon steel strip. The metal alloyin the melting pot is at a temperature of about 301-455° C. The carbonsteel strip is passed through the melting pot having a length of about16 feet at a speed of about 100 ft/min. The carbon steel strip has aresident time in the melting pot of less than about 10 seconds. Thecoated carbon steel strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-77 microns. Thecoated carbon steel strip is rewound into a roll of coated carbon steelstrip.

EXAMPLE M

[0233] A carbon steel strip is unwound from a roll of carbon steelstrip. The carbon steel strip has a thickness of less than about 762microns. The carbon steel strip is plated with chromium of a thicknessof less than about 3 microns. A metal alloy having a composition of atleast about 98% tin and zinc, less than about 1% of a metal additive,less than about 0.1% lead is coated onto the carbon steel strip. Themetal alloy is heated in a melting pot at a temperature of about301-482° C. The carbon steel strip is passed through the melting pothaving a length of about 16 feet at a speed of about 100 ft/min. Thecarbon steel strip has a resident time in the melting pot of less thanabout 10 seconds. The coated carbon steel strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-77 microns. The coated carbon steel strip is rewound into a rollof coated carbon steel strip.

EXAMPLE N

[0234] A copper strip is unwound from a roll of copper strip. The copperstrip has a thickness of less than about 762 microns. The copper stripis continuously plated with a tin layer of about 1-3 microns thick. Ametal alloy having a composition of at least about 99% tin and zinc iscoated onto the copper strip. The metal alloy is heated in a melting potat a temperature of about 301-482° C. The coated strip is passed throughthe melting pot having a length of about 16 feet at a speed of about 100ft./min. The copper strip has a resident time in the melting pot of lessthan about 10 seconds. The coated copper strip is passed through coatingrollers and/or an air-knife to achieve a coating thickness of about 7-77microns. The coated copper strip is rewound into a roll of coated copperstrip.

EXAMPLE O

[0235] A carbon steel strip is unwound from a roll of carbon steel stripand continuously plated with a tin layer of a thickness of less thanabout 3 microns. The carbon steel strip has a thickness of less thanabout 762 microns. A metal alloy having a composition of at least about98% tin and zinc, and less than about 0.1% lead is coated onto thecarbon steel strip. The metal alloy is heated in a melting pot at atemperature of about 301-427° C. The carbon steel strip is passedthrough the melting pot having a length of about 16 feet at a speed ofabout 100 ft/min. The carbon steel strip has a resident time in themelting pot of less than about 10 seconds. The coated carbon steel stripis passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-77 microns. The coated carbon steel stripis rewound into a roll of coated carbon steel strip.

EXAMPLE P

[0236] A stainless steel strip is unwound from a roll of stainless steelstrip. The stainless steel strip is continuously plated with a tin layerof about 1-3 microns thick. The stainless steel strip has a thickness ofless than about 762 microns. A metal alloy having a composition of atleast about 98-99% tin and zinc is heated in a melting pot at atemperature of about 301-427° C. The stainless steel strip is passedthrough the melting pot having a length of about 16 feet at a speed ofabout 100 ft/min. The stainless steel strip has a resident time in themelting pot of less than about 10 seconds. The coated stainless steelstrip is passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-77 microns. The coated stainless steelstrip is rewound into a roll of coated stainless steel strip.

EXAMPLE Q

[0237] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and a copper sulfatesolution. Copper is plated onto the carbon steel strip surface duringthe pickling process to form a copper layer of about 1-3 microns thick.The carbon steel strip has a thickness of less than about 762 microns. Ametal alloy having a composition of at least about 95-99% tin and zinc,and less than about 0.2% lead is coated onto the carbon steel strip. Themetal in a melting pot is heated to a temperature of about 301-482° C.The carbon steel strip is passed through the melting pot having a lengthof about 16 feet at a speed of about 100 ft/min. The carbon steel striphas a resident time in the melting pot of less than about 10 seconds.The coated carbon steel strip is passed through coating rollers and/oran air-knife to achieve a coating thickness of about 7-77 microns. Thecoated carbon steel strip is rewound into a roll of coated carbon steelstrip.

EXAMPLE R

[0238] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and chemicallyactivated with a zinc chloride solution prior to coating. The carbonsteel strip has a thickness of less than about 762 microns. The carbonsteel strip is not pre-heated prior to coating. A metal alloy having acomposition of about 90-95% tin, and less than about 0.5% lead is coatedonto the carbon steel strip. The metal alloy in the melting pot isheated to a temperature of about 238-246° C. The melting pot is heatedby four external gas torches directed to the outer sides of the meltingpot. The carbon steel strip is passed through the melting pot having alength of about 16 feet at a speed of about 100 ft/min. The carbon steelstrip has a resident time in the melting pot of less than about 10seconds. The coated carbon steel is passed through coating rollersand/or an air-knife to achieve a coating thickness of about 7-51microns. The coated carbon steel strip is then cooled and rewound into aroll of coated carbon steel strip.

EXAMPLE S

[0239] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and chemicallyactivated with a zinc chloride solution prior to coating. The carbonsteel strip has a thickness of less than about 762 microns. The carbonsteel strip is plated with chromium of a thickness of less than about 3microns. The carbon steel strip is not pre-heated prior to coating. Ametal alloy having a composition of about 90-99% tin, about 0.01-1%metallic stabilizer selected from antimony, bismuth and/or copper, andless than about 0.5% lead is coated onto the carbon steel strip. Themetal alloy is heated in a melting pot at a temperature of about238-482° C. The melting pot is heated by four external gas torchesdirected to the outer sides of the melting pot. The carbon steel stripis passed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The carbon steel strip has a resident time inthe melting pot of less than about 10 seconds. The coated carbon steelstrip is passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-51 microns. The coated carbon steel stripis then cooled and rewound into a roll of coated carbon steel strip.

EXAMPLE T

[0240] A copper strip is unwound from a roll of copper strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The copper strip has athickness of less than about 762 microns. The copper strip is notpre-heated prior to coating. A metal alloy having a composition of about90-99% tin, 0-1% metallic stabilizer, and less than about 0.1% lead iscoated onto the copper strip. The metal alloy is heated in a melting potat a temperature of about 238-246° C. The melting pot is heated by fourexternal gas torches directed to the outer sides of the melting pot. Thecopper strip is passed through the melting pot having a length of about16 feet at a speed of about 100 ft./min. The copper strip has a residenttime in the melting pot of less than about 10 seconds. The coated copperstrip is passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-51 microns. The coated copper strip is thencooled and rewound into a roll of coated copper strip.

EXAMPLE U

[0241] A carbon steel strip is unwound from a roll of carbon steel stripand plated with a nickel layer of a thickness of less than about 3microns. The carbon steel strip has a thickness of less than about 762microns. The carbon steel strip is not pre-heated prior to coating. Ametal alloy having a composition of about 90-99% tin, and less thanabout 0.1% lead is coated onto the carbon steel strip. The metal alloyis heated in a melting pot at a temperature of about 238-255° C. Themelting pot is heated by four external gas torches directed to the outersides of the melting pot. The carbon steel strip is passed through thecoating tank having a length of about 16 feet at a speed of about 100ft/min. The carbon steel strip has a resident time in the melting pot ofless than about 10 seconds. The coated carbon steel strip is passedthrough coating rollers and/or an air-knife to achieve a coatingthickness of 7-51 microns. The coated carbon steel strip is then cooledand rewound into a roll of coated carbon steel strip.

EXAMPLE V

[0242] A stainless steel strip is unwound from a roll of stainless steelstrip and is aggressively pickled with a dual acid solution ofhydrochloric acid and nitric acid and chemically activated with a zincchloride solution. The stainless steel strip is plated with a nickellayer of about 1-3 microns thick. The stainless steel strip has athickness of less than about 762 microns. The stainless steel strip isnot pre-heated prior to coating. A metal alloy having a composition ofabout 90-99% tin and is heated in a melting pot at a temperature ofabout 238-260° C. The melting pot is heated by four external gas torchesdirected to the outer sides of the melting pot. The stainless steelstrip is passed through the melting pot having a length of about 16 feetat a speed of about 100 ft/min. The stainless steel strip has a residenttime in the melting pot of less than about 10 seconds. The coatedstainless steel strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-51 microns. Thecoated stainless steel strip is then cooled and rewound into a roll ofcoated stainless steel strip.

EXAMPLE W

[0243] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and a copper sulfatesolution and chemically activated with a zinc chloride solution prior tocoating. Copper is plated onto the carbon steel strip surface during thepickling process to form a copper layer of about 1-3 microns thick. Thecarbon steel strip has a thickness of less than about 762 microns. Thecarbon steel strip is not pre-heated prior to coating. A metal alloyhaving a composition of about 90-95% tin and less than about 0.5% leadis coated onto the carbon steel strip. The metal alloy is heated in amelting pot at a temperature of about 238-250° C. The melting pot isheated by four external gas torches directed to the outer sides of themelting pot. The carbon steel strip is passed through the melting pothaving a length of about 16 feet at a speed of about 100 ft/min. Thecarbon steel strip has a resident time in the melting pot of less thanabout 10 seconds. The coated carbon steel strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-51 microns. The coated carbon steel strip is then cooled andrewound into a roll of coated carbon steel strip.

EXAMPLE X

[0244] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and chemicallyactivated with a zinc chloride solution prior to coating. The carbonsteel strip has a thickness of more than about 762 microns. The carbonsteel strip is pre-heated prior to coating. A metal alloy having acomposition of about 90-99% tin and less than about 0.1% lead is coatedonto the carbon steel strip. The metal alloy is heated in a melting potat a temperature of about 237-246° C. The melting pot is heated by fourexternal gas torches directed to the outer sides of the melting pot. Thecarbon steel strip is passed through the melting pot having a length ofabout 16 feet at a speed of about 100 ft/min. The carbon steel strip hasa resident time in the melting pot of less than about 10 seconds. Thecoated carbon steel strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-51 microns. Thecoated carbon steel strip is then cooled and rewound into a roll ofcoated carbon steel strip.

EXAMPLE Y

[0245] A thin strip of carbon steel uncoiled from a roll of carbon steelis passed through an electroplating bath to deposit an ultra thin layerof tin on the carbon steel strip. The carbon steel strip had a thicknessof less than about 762 microns. The carbon steel strip is then coatedwith a two-phase zinc-tin coating to produce an intermetallic layerbetween the metal alloy and the carbon steel strip. The tin-zinc alloyhas a coating of tin and zinc content at least about 75 weight percent.

EXAMPLE Z

[0246] The process of Example Y was performed with the addition of aheating furnace to flow heat the thin tin plating and, thus, form a heatcreated intermetallic layer including iron and tin prior to the metalalloy coating process.

EXAMPLE AA

[0247] The process of Example Y was performed with copper being platedon the carbon steel strip by an electrolytic bath.

EXAMPLE BB

[0248] A copper strip is unwound from a roll of copper strip. The copperstrip has a thickness of less than about 762 microns. The copper stripis pickled with an acid to clean the surface of the copper strip. Thecopper strip is continuously passed through an electrolytic tank toplate nickel on the copper strip surface. The nickel plated layer has athickness of about 1-3 microns. The copper strip is no preheated. Ametal alloy having a composition of at least about 95% tin and zinc, andless than about 0.5% lead is coated onto the copper strip. The metalalloy is in a melting pot at a temperature of about 301-454° C. Thecopper strip is passed through the melting pot having a length of about16 feet at a speed of about 100 ft/min. The copper strip has a residenttime in the melting pot of less than about 10 seconds. The coated copperstrip is passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-77 microns. The coated copper strip isrewound into a roll of coated copper strip.

EXAMPLE CC

[0249] A brass strip is unwound from a roll of brass strip. The brassstrip has a thickness of less than about 762 microns. The brass strip ispickled to remove surface oxides. The brass strip is plated withchromium having a thickness of less than about 3 microns. The brassstrip is not preheated. A metal alloy having a composition of at leastabout 98% tin and zinc, less than about 1% of a metal additive, and lessthan about 0.1% lead is coated onto the brass strip. The metal alloy isheated in a melting pot at a temperature of about 301-482° C. The brassstrip is passed through the melting pot having a length of about 16 feetat a speed of about 100 ft/min. The brass strip has a resident time inthe melting pot of less than about 10 seconds. The coated brass strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated brass strip is rewound intoa roll of coated brass strip.

EXAMPLE DD

[0250] A bronze strip is unwound from a roll of bronze strip. The bronzestrip has a thickness of less than about 762 microns. The copper stripis continuously plated with a tin layer of about 1-3 microns thick. Ametal alloy having a composition of at least about 99% tin and zinc iscoated onto the bronze strip. The metal alloy is heated in a melting potat a temperature of about 301-482° C. The bronze strip is passed throughthe melting pot having a length of about 16 feet at a speed of about 100ft./min. The bronze strip has a resident time in the melting pot of lessthan about 10 seconds. The coated bronze strip is passed through coatingrollers and/or an air-knife to achieve a coating thickness of about 7-77microns. The coated bronze strip is rewound into a roll of coated bronzestrip.

EXAMPLE EE

[0251] A carbon steel strip is unwound from a roll of carbon steel stripand continuously plated with a tin layer of a thickness of less thanabout 3 microns. The carbon steel strip has a thickness of less than 762microns. A metal alloy having a composition of at least about 98% tinand zinc, and less than about 0.1% lead is coated onto the carbon steelstrip. The metal alloy is plated and subsequently flow heated onto thesurface of the carbon steel strip. The coated carbon steel strip ispassed through an air-knife to achieve a coating thickness of about 7-77microns. The coated carbon steel strip is oxidized to expose the heatcreated intermetallic layer. The oxidized carbon steel strip is rewoundinto a roll of oxidized carbon steel strip.

EXAMPLE FF

[0252] A stainless steel strip is unwound from a roll of stainless steelstrip. The stainless steel strip is aggressively pickled and chemicallyactivated to clean the stainless steel strip surface. The stainlesssteel strip is continuously plated with a tin layer of about 1-3 micronsthick. The stainless steel strip has a thickness of less than about 762microns. The stainless steel strip is preheated. A metal alloy having acomposition of at least about 98-99% tin and zinc is heated in a meltingpot at a temperature of about 301-427° C. The stainless steel strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The stainless steel strip has a resident timein the melting pot of less than about 10 seconds. The coated stainlesssteel strip is passed through coating rollers and/or an air-knife toachieve a coating thickness of about 7-77 microns. The coated stainlesssteel strip is oxidized to expose the heat created intermetallic layer.The oxidized stainless steel strip is rewound into a roll of oxidizedstainless steel strip.

EXAMPLE GG

[0253] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and a copper sulfatesolution. Copper is plated onto the carbon steel strip surface duringpickling to form a copper layer of about 1-3 microns thick. The carbonsteel strip has a thickness of less than about 762 microns. A metalalloy having a composition of at least about 95-99% tin and zinc, andless than about 0.2% lead is coated onto the carbon steel strip. Themetal alloy is plated and subsequently flow heated onto the carbon steelstrip. The coated carbon steel strip is passed through coating rollersand/or an air-knife to achieve a coating thickness of about 7-77microns. The coated carbon steel strip is rewound into a roll of coatedcarbon steel strip.

EXAMPLE HH

[0254] A brass strip is unwound from a roll of brass strip. The brassstrip has a thickness of less than about 762 microns. The brass iscontinuously passed through an electrolytic tank to plate nickel on thebrass strip surface. The nickel plated layer has a thickness of about1-3 microns. A metal alloy having a composition of 95-98% tin and zinc,and less than about 0.5% lead is coated onto the brass strip. The metalalloy in a melting pot is heated to a temperature of about 301-455° C.The carbon steel strip is passed through the melting pot having a lengthof about 16 feet at a speed of about 100 ft/min. The brass strip has aresident time in the melting pot of less than about 10 seconds. Thecoated brass strip is passed through coating rollers and/or an air-knifeto achieve a coating thickness of about 7-77 microns. The coated brassstrip is rewound into a roll of coated brass strip.

EXAMPLE II

[0255] A tin strip is unwound from a roll of tin strip. The tin striphas a thickness of less than about 762 microns. The tin strip is platedwith chromium of a thickness of less than about 3 microns. A metal alloyhaving a composition of about 95-98% tin and zinc, less than about 2% ofa metal additive, and less than about 0.5% lead is coated onto the tinstrip. The metal alloy is heated in a melting pot at a temperature ofabout 301-482° C. The tin strip is passed through the melting pot havinga length of about 16 feet at a speed of about 100 ft/min. The tin striphas a resident time in the melting pot of less than about 10 seconds.The coated tin strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-77 microns. Thecoated tin strip is rewound into a roll of coated tin strip.

EXAMPLE JJ

[0256] A copper strip is unwound from a roll of copper strip. The copperstrip has a thickness of less than about 762 microns. The copper stripis continuously plated with a tin layer of about 1-3 microns thick. Ametal alloy having a composition of about 90-99% tin and 0-5% lead iscoated onto the copper strip. The metal alloy is heated in a melting potat a temperature of about 301-482° C. The copper strip is passed throughthe melting pot having a length of about 16 feet at a speed of about 100ft./min. The copper strip has a resident time in the melting pot of lessthan about 10 seconds. The coated copper strip is passed through coatingrollers and/or an air-knife to achieve a coating thickness of about 7-77microns. The coated copper strip is rewound into a roll of coated copperstrip.

EXAMPLE KK

[0257] A carbon steel strip is unwound from a roll of carbon steel stripand continuously plated with a tin layer of a thickness of less thanabout 3 microns. The carbon steel strip has a thickness of less thanabout 762 microns. A metal alloy having a composition of about 90-99%tin and zinc, and less than about 0.5% lead is coated onto the carbonsteel strip. The metal alloy is heated in a melting pot at a temperatureof about 301-482° C. The carbon steel strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft/min. The carbon steel has a resident time in the melting pot of lessthan about 10 seconds. The coated carbon steel strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-77 microns. The coated carbon steel strip is rewound into a rollof coated carbon steel strip.

EXAMPLE LL

[0258] A stainless steel strip is unwound from a roll of stainless steelstrip. The stainless steel strip is continuously plated with a tin layerof about 1-3 microns thick. The stainless steel strip has a thickness ofless than about 762 microns. A metal alloy having a composition of about90-99% tin and zinc is heated in a melting pot at a temperature of about301-482° C. The stainless steel strip is passed through the melting pothaving a length of about 16 feet at a speed of about 100 ft/min. Thestainless steel strip has a resident time in the melting pot of lessthan about 10 seconds. The coated stainless steel strip is passedthrough coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated stainless steel strip isrewound into a roll of coated stainless steel strip.

EXAMPLE MM

[0259] A brass strip is unwound from a roll of brass strip and ispickled with a hydrochloric acid solution and a copper sulfate solution.Copper is plated onto the carbon steel strip surface during pickling toform a copper layer of about 1-3 microns thick. The brass strip has athickness of less than about 762 microns. A metal alloy having acomposition of about 90-95% tin, and less than about 0.5% lead is heatedin a melting pot at a temperature of about 301-482° C. The brass stripis passed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The brass strip has a resident time in themelting pot of less than about 10 seconds. The coated brass strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated brass strip is rewound intoa roll of coated brass strip.

EXAMPLE NN

[0260] A copper strip is unwound from a roll of copper strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The copper strip has athickness of less than about 762 microns. The copper strip is notpre-heated prior to coating. A tin alloy having a composition of about90-99% tin, and less than about 2% lead is heated in a melting pot at atemperature of about 237-246° C. The copper strip is passed through themelting pot at a speed of about 100 ft/min. The copper strip has aresident time in the coating tank of less than about 10 seconds. Thecoated copper strip is passed through coating rollers and/or an airknife to achieve a coating thickness of about 7-51 microns. The coatedcopper strip is then cooled. The coated copper strip is then oxidized toremove the coated tin alloy and to expose and pacify the heat createdintermetallic layer. The copper strip is then wound into a roll ofcopper strip.

EXAMPLE OO

[0261] A copper strip is unwound from a roll of copper strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The copper strip has athickness of less than about 762 microns. The copper strip is platedwith nickel having a thickness of less than about 3 microns. The copperstrip is preheated prior to coating. A tin alloy having a composition ofabout 90-99% tin, and less than about 2% lead is heated in a melting potat a temperature of about 237-482° C. The copper strip is passed throughthe melting pot at a speed of about 100 ft/min. The copper strip has aresident time in the melting pot of less than about 10 seconds. Thecoated copper strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of 7-51 microns. The coatedcopper strip is cooled and then oxidized to remove the tin alloy and toexpose and pacify the heat created intermetallic layer. The copper stripis then wound into a roll of copper strip.

EXAMPLE PP

[0262] A copper strip is unwound from a roll of copper strip. The copperstrip has a thickness of less than about 762 microns. The strip is notpre-heated prior to coating. A tin alloy having a composition of about99% tin, and less than about 0-5% lead is applied to the copper strip byan electroplating process. The plated copper strip is then flow heatedfor less than about 5 minutes. The coated copper strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-51 microns. The coated copper strip is then cooled. The coatedcopper strip is then oxidized to remove the tin alloy and to expose andpacify the heat created intermetallic layer. The copper strip is thenwound into a roll of copper strip.

EXAMPLE QQ

[0263] A copper steel strip is unwound from a roll of copper strip andplated with a chromium layer having a thickness of less than about 3microns. The copper strip has a thickness of less than about 762microns. The copper strip is pre-heated prior to coating. A tin alloyhaving a composition of about 90-99% tin, and less than about 0-1% leadis coated onto the copper strip. The copper strip is passed through ametal spaying process at a speed of up to about 100 ft/min. The coatedcopper strip is then passed through coating rollers and/or an air-knifeto achieve a coating thickness of about 7-51 microns. The coated copperstrip is cooled and then oxidized to remove the tin alloy to expose andpacify the heat created intermetallic layer. The copper strip is thencut into sheets.

EXAMPLE RR

[0264] A copper strip is unwound from a roll of copper strip and ispickled with an acid solution and then chemically activated with achemical activation solution. The copper strip is plated with a metallayer of about 1-3 microns thick. The copper strip is not pre-heatedprior to coating. A tin alloy having a composition of about 90-99% tinis metal sprayed onto the copper strip. The coated copper strip is thenpassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-51 microns. The coated copper strip is then cooledand wound into a roll of copper strip. The roll of coated copper stripis later formed into roofing materials and installed on a building. Theformed coated copper strip is then exposed on site to an oxidizingsolution to remove the tin alloy and expose and pacify the intermetalliclayer.

EXAMPLE SS

[0265] A tin strip is unwound from a roll of tin strip. The tin striphas a thickness of less than about 762 microns. The tin strip iscontinuously passed through an electrolytic tank to plate nickel on thetin strip surface. The nickel plated layer has a thickness of about 1-3microns. A metal alloy having a composition of at least about 85% tin,at least about 10% zinc, and less than about 0.5% lead is heated in amelting pot at a temperature of about 301-455° C. The tin strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The tin strip has a resident time in themelting pot of less than about 10 seconds. The coated tin strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated tin strip is rewound into aroll of coated tin strip.

EXAMPLE TT

[0266] A bronze strip is unwound from a roll of bronze strip. The bronzestrip has a thickness of less than about 762 microns. The bronze stripis plated with chromium of a thickness of less than about 3 microns. Ametal alloy having a composition of at least about 45% tin, at leastabout 45% zinc, less than about 1% of a metal additive, and less thanabout 0.1% lead is heated in a melting pot at a temperature of about301-482° C. The bronze strip is passed through the melting pot having alength of about 16 feet at a speed of about 100 ft/min. The bronze striphas a resident time in the melting pot of less than about 10 seconds.The coated bronze strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-77 microns. Thecoated bronze strip is rewound into a roll of coated bronze strip.

EXAMPLE UU

[0267] A aluminum strip is unwound from a roll of aluminum strip. Thealuminum strip has a thickness of less than about 762 microns. Thealuminum strip is continuously plated with a tin layer of about 1-3microns thick. A metal alloy having a composition of at least about 45%tin and at least about 45% zinc is heated in a melting pot at atemperature of about 301-482° C. The aluminum strip is passed throughthe melting pot having a length of about 16 feet at a speed of about 100ft./min. The aluminum strip has a resident time in the melting pot ofless than about 10 seconds. The coated aluminum strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-77 microns. The coated aluminum strip is rewound into a roll ofcoated aluminum strip.

EXAMPLE W

[0268] A tin strip is unwound from a roll of tin strip and continuouslyplated with a tin layer of a thickness of less than about 3 microns. Thetin strip has a thickness of less than about 762 microns. A metal alloyhaving a composition of at least about 45% tin, at least about 45% zinc,and less than about 0.1% lead is heated in a melting pot at atemperature of about 301-427° C. The tin strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft/min. The tin has a resident time in the melting pot of less thanabout 10 seconds. The coated tin strip is passed through coating rollersand/or an air-knife to achieve a coating thickness of about 7-77microns. The coated tin strip is rewound into a roll of coated tinstrip.

EXAMPLE WW

[0269] A brass strip is unwound from a roll of brass strip. The brassstrip is continuously plated with a-tin layer of about 1-3 micronsthick. The brass strip has a thickness of less than about 762 microns. Ametal alloy having a composition of at least about 20% tin, and at leastabout 75% zinc is heated in a melting pot at a temperature of about301-427° C. The brass strip is passed through the melting pot having alength of about 16 feet at a speed of about 100 ft/min. The brass striphas a resident time in the melting pot of less than about 10 seconds.The coated brass strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-77 microns. Thecoated brass strip is rewound into a roll of coated brass strip.

EXAMPLE XX

[0270] A brass strip is unwound from a roll of brass strip and ispickled with a hydrochloric acid solution and a copper sulfate solution.Copper is plated onto the brass strip surface during pickling to form acopper layer of about 1-3 microns thick. The brass strip has a thicknessof less than about 762 microns. A metal alloy having a composition of atleast about 70% tin, at least about 25% zinc, and less than about 0.2%lead is heated in a melting pot at a temperature of about 301-482° C.The brass strip is coated by metal strap jets. The coated brass strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated brass strip is rewound intoa roll of coated brass strip.

EXAMPLE YY

[0271] A brass strip is unwound from a roll of brass strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The brass strip has athickness of less than about 762 microns. The brass strip is notpre-heated prior to coating. A tin alloy having a composition of about90-99% tin, and less than about 2% lead is heated in a melting pot at atemperature of about 237-246° C. The brass strip is passed through themelting pot at a speed of about 100 ft/min. The brass strip has aresident time in the melting pot of less than about 10 seconds. Thecoated brass strip is passed through coating rollers and/or an air knifeto achieve a coating thickness of about 7-51 microns. The coated brassstrip is then cooled. The coated brass strip is then oxidized to removethe coated tin alloy to expose and pacify the heat created intermetalliclayer. The brass strip is then wound into a roll of brass strip.

EXAMPLE ZZ

[0272] A brass strip is unwound from a roll of brass strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The brass strip has athickness of less than about 762 microns. The brass strip is plated withnickel having a thickness of less than about 3 microns. The brass stripis preheated prior to coating. A tin alloy having a composition of about90-99% tin, and less than about 2% lead is heated in a melting pot at atemperature of about 237-482° C. The brass strip is passed through themelting pot at a speed of about 100 ft/min. The brass strip has aresident time in the melting pot of less than about 10 seconds. Thecoated brass strip is passed through coating rollers and/or an air-knifeto achieve a coating thickness of about 7-51 microns. The coated brassstrip is cooled and then oxidized to remove the tin alloy to expose andpacify the heat created intermetallic layer. The brass strip is thenwound into a roll of brass strip.

EXAMPLE AAA

[0273] A brass strip is unwound from a roll of brass strip. The brassstrip has a thickness of less than about 762 microns. The brass strip ispickled to clean the brass strip surface. The brass strip is notpre-heated prior to coating. A tin alloy having a composition of about99% tin, and less than about 0-5% lead is applied to the brass strip byan electroplating process. The plated brass strip is then flow heatedfor less than about 5 minutes. The coated brass strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-51 microns. The coated brass strip is then cooled. The coatedbrass strip is then oxidized to remove the tin alloy and to expose andpacify the heat created intermetallic layer. The brass strip is thenwound into a roll of brass strip.

EXAMPLE BBB

[0274] A brass strip is unwound from a roll of brass strip and platedwith a zinc layer having a thickness of less than about 3 microns. Thebrass strip has a thickness of less than about 762 microns. The brassstrip is pre-heated prior to coating. A tin alloy having a compositionof about 90-99% tin, and less than about 0-1% lead is passed through ametal spaying process at a speed of up to 100 ft/min. The coated brassstrip is then passed through coating rollers and/or an air-knife toachieve a coating thickness of about 7-51 microns. The coated brassstrip is cooled and then oxidized to remove the tin alloy and to exposeand pacify the heat created intermetallic layer. The brass strip is thencut into sheets.

EXAMPLE CCC

[0275] A brass strip is unwound from a roll of brass strip and ispickled with an acid solution and then chemically activated with achemical activation solution. The brass strip is plated with a metallayer of about 1-3 microns thick. The brass strip is not pre-heatedprior to coating. A tin alloy having a composition of about 90-99% tinis plated onto the brass strip and then flow heated. The brass strip isthen coated again by a spray metal process. The coated brass strip isthen passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-51 microns. The coated brass strip is thencooled and wound into a roll of brass strip. The roll of coated brassstrip is formed into roofing materials and installed on a building. Theformed coated strip is then exposed on site to an oxidizing solution toremove the tin alloy and to expose and to pacify the intermetalliclayer.

EXAMPLE DDD

[0276] A copper metal strip is unwound from a roll of copper metalstrip. The copper metal strip has a thickness of less than about 762microns. A metal alloy having a composition of about 40-60% tin andabout 40-60% zinc is coated onto the copper metal strip. The coppermetal strip is passed through the melting pot having a length of atleast about 5 feet at a speed of about 20-100 ft./min. The copper metalstrip has a resident time in the melting pot of less than about 100seconds. The coated copper metal strip is passed through coating rollersand/or an air-knife to achieve a coating thickness of about 3-77microns. FIG. 22 illustrates the copper base metal 300 coated with thetin and zinc alloy 320. A heat created intermetallic layer 310 is alsoillustrated between tin and zinc alloy 320 and copper base metal 300. Asbest illustrated in FIG. 23, the thickness of the intermetallic layerand the tin and zinc alloy are about the same. The thickness of each ofthese layer is about 3-10 microns, and typically about 4-8 microns. Assuch, the total thickness of the heat created intermetallic layer plusthe tin and zinc alloy is about 3-20 microns, and typically 8-16microns. As can be appreciated, the residence time of the copper metalstrip in the melting pot can be selected to created thicker or thinnerlayers. The thickness of the copper metal strip illustrated in FIG. 22is about 200-600 microns and typically about 240-480 microns. As can beappreciated, thicker or thinner copper metal strip can be used. A uniquephenomena was discovered when analyzing the composition of the tin andzinc top coating and the heat created intermetallic layer. Asillustrated by the graphs in FIG. 23, the composition of heat createdintermetallic layer is principally copper and zinc. The graphillustrates that little, if any, tin is included in the heat createdintermetallic layer 310. Apparently, the molten tin in the tin and zincalloy has significantly less affinity than the zinc to combine with thecopper in the heated interface between the copper metal strip and themolten tin and zinc. The zinc appears to have partially migrated fromthe tin and zinc alloy and into the copper to form a copper-zinc heatcreated intermetallic layer. The composition of the tin and zinc layer320 is also interesting at the interface with the heat createdintermetallic layer. Upon crossing the interface into the tin and zincalloy coating, little, if any, copper is present in the tin and zincalloy coating. The distribution of the zinc in the tin for the tin andzinc coating was also interesting. The tin and zinc layer was found tobe porous and include scattered small fingers of zinc penetratingthrough the tin to the surface of the tin and zinc coating. The reasonsfor these phenomena are presently not known to the inventors. The coatedcopper metal strip was subjected to various types of environments. Theresults of these tests revealed that the bonding of the tin and zincalloy to the copper metal strip was very strong, thus exhibited little,if any, flaking. The teats also revealed that the coated copper metalstrip had excellent corrosion resistant properties. In environments thatexposed the coated copper metal strip to water, the coated copper metalstrip exhibited excellent corrosion resistant properties. Applicantsbelieve that the formation of the copper and zinc heat createdintermetallic layer is facilitated by the fact that the zinc content inthe tin and zinc alloy is above the eutectic point of the tin and zincalloy. As such, the globules of zinc in the tin and zinc alloy are ablethe combine with the copper to form the copper and zinc heat createdintermetallic layer. As such, tin and zinc coatings that include atleast 10 weight percent zinc readily form a copper and zinc heat createdintermetallic layer when such a tin and zinc alloy is coated on thecopper metal strip. Copper metal strip that is coated with a tin alloythat includes less than 10 weight percent zinc will form a copper andzinc heat created intermetallic layer to a lesser degree. When using atin alloy coating, the zinc content should be at least about 5 to up toabout 10 weight percent of the coating so as to form a significantcopper-zinc heat created intermetallic layer. The formation of thehighly corrosion resistant copper and zinc intermetallic layer will bepresent in copper alloy metal strip that is coated with a tin and zincalloy or tin alloy having a significant amount of zinc (e.g., at leastabout 5 weight percent), and also in a non-copper or non-copper alloymetal strip that has been plated, clad, brazened, hot dipped, etc. witha copper or copper alloy layer and then coated with a tin and zinc alloyor tin alloy having a significant amount of zinc.

EXAMPLE EEE

[0277] A carbon steel metal strip is unwound from a roll of carbon steelmetal strip. The carbon steel metal strip has a thickness of less thanabout 762 microns. The carbon steel strip is plated with a copper layerof about 1-6 microns thick. A metal alloy having a composition of about40-60% tin and about 40-60% zinc is coated onto the carbon steel metalstrip. The carbon steel metal strip is passed through the melting pothaving a length of at least about 5 feet at a speed of about 20-100ft./min. The carbon steel metal strip has a resident time in the meltingpot of less than about 100 seconds. The coated carbon steel metal stripis passed through coating rollers and/or an air-knife to achieve acoating thickness of about 3-77 microns. A heat created intermetalliclayer was formed that principally included copper and zinc. The tin andzinc layer was found to be porous and included scattered small fingersof zinc penetrating through the tin to the surface of the tin and zinccoating. Improved corrosion resistance was observed in the heat createdintermetallic layer when the thickness of the plated copper later wasover about 1 micron.

EXAMPLE FFF

[0278] A carbon steel metal strip is unwound from a roll of carbon steelmetal strip. The carbon steel metal strip has a thickness of less thanabout 762 microns. The carbon steel strip is plated with a copper layerof about 1-6 microns thick. A metal alloy having a composition of about91-95% tin and about 5-9% zinc is coated onto the carbon steel metalstrip. The carbon steel metal strip is passed through the melting pothaving a length of at least about 5 feet at a speed of about 20-100ft./min. The carbon steel metal strip has a resident time in the meltingpot of less than about 100 seconds. The coated carbon steel metal stripis passed through coating rollers and/or an air-knife to achieve acoating thickness of about 3-77 microns. A heat created intermetalliclayer was formed that principally included copper and zinc. The tinlayer was found to included tin and zinc. Improved corrosion resistancewas observed in the heat created intermetallic layer when the thicknessof the plated copper later was over about 1 micron.

EXAMPLE GGG

[0279] This example is similar to Example EEE and FFF except that thebase metal strip is stainless steel instead of carbon steel. Thephenomena concerning the composition of the heat created intermetalliclayer and the tin and zinc alloy coating as set forth in Example EEE andFFF also existed in the coated stainless steel metal strip.

EXAMPLE HHH

[0280] A metal alloy is formed into a metal strip to be formed tovarious types of materials, or into a solder or a welding wire forconnecting two or more metal materials together. One general compositionof the metal strip, solder or welding wire is 20-70% tin, 30-75% zinc,0.0005-2% aluminum, 0.001-2% antimony, 0.0001-1% bismuth, 0-2% copper,0-0.5% lead, 0.0001-0.1% titanium. Another and/or alternativeformulation of the metal strip, solder or welding wire is 40-60% tin,40-60% zinc, 0.0005-0.75% aluminum, 0.001-1% antimony, 0.0001-0.2%bismuth, 0-0.01% arsenic, 0-0.01% cadmium, 0-0.01% chromium, 0.001-1%copper, 0-0.1% iron, 0-0.1% lead, 0-0.01% manganese, 0-0.2% nickel,0-0.01% silver, 0.0005-0.05% titanium. Still another and/or alternativeformulation of the metal strip, solder or welding wire includes 30-70%tin; 30-70% zinc; 0.0001-0.5% aluminum; 0.001-2% antimony; 0-0.01%arsenic; 0.0001-1% bismuth; 0-0.01% boron; 0-0.01% cadmium; 0-0.05%carbon; 0-0.05% chromium; 0-2% copper; 0-0.1% iron; 0-0.5% lead; 0-0.01%magnesium; 0-0.01% manganese; 0-0.01% molybdenum; 0-1% nickel; 0-0.01%silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0.0001-0.1%titanium; and 0-0.01% vanadium. Yet another and/or alternativeformulation of the metal strip, solder or welding wire is 40-60% tin;40-60% zinc; 0.0005-0.4% aluminum; 0.01-0.8% antimony; 0-0.005% arsenic;0.001-0.05% bismuth; 0-0.005% cadmium; 0.005-0.5% copper; 0-0.05% iron;0-0.1% lead; 0-0.05% nickel; 0-0.005% silver; and 0.0005-0.05% titanium.Still yet a further and/or alternative formulation of the metal strip,solder or welding wire is 48-52% tin; 48-52% zinc; 0.005-0.24% aluminum;0.05-0.64% antimony; 0-0.001% arsenic; 0.002-0.005% bismuth; 0-0.001%cadmium; 0.01-0.3% copper; 0-0.016% iron; 0-0.08% lead; 0-0.001% nickel;0-0.001% silver; 0.001-0.02% titanium. Another and/or alternativeformulation of the metal strip, solder or welding wire is 5-70% tin;30-95% zinc; 0-0.25% aluminum; 0-0.02% chromium; 0-1.5% copper; 0-0.01%iron; 0-0.01% lead; 0-0.01% manganese; and 0-0.18% titanium. When themetal alloy is used as a solder metal or electrode, the metal alloy istypically formed into a thin wire or thin strip by common knownprocesses. The thin wire or thin strip is typically rolled for laterprocessing or use. The metal alloy made for solder typically includesaluminum and/or titanium since these two metal additives positivelyaffect the surface tension of the metal alloy in the molten state sothat the molten metal alloy has the desired wetting characteristics. Thehigher the concentration of titanium and/or aluminum, the more thesolder will bead when applied to a workpiece. The addition of titaniumand/or aluminum to the metal alloy also causes the metal alloy to resistflowing at temperatures near the melting point of the metal alloy. Thisresistance imparts excellent soldering characteristics. The titaniumand/or aluminum are believed to cause oxide formation on the surface ofthe molten solder to form a dull greyish, earth tone colored solder. Thetitanium and aluminum are also believe to assist in forming anintermetallic layer with the tin and zinc in the metal alloy and theworkpiece before solidification of the solder to thereby form a strongbond with the workpiece. The solder typically includes little, if any,lead additions, and such, any lead in the solder is typically due toimpurities. The solder composition is particularly useful in solderingcarbon steel, stainless steel, copper, copper alloys, tin, tin alloys,zinc and zinc alloys. However, the solder can be used on other types ofmetals. If the solder is to be used to connect copper or copper alloys,copper is typically added to the metal alloy composition. The additionof copper reduces the reactivity of the solder with the copper or copperalloy materials. The solder may be used with a wide variety of fluxes.If the solder is to be used in ultrasonic welding, a flux is typicallynot used.

EXAMPLE III

[0281] The metal alloy is used for standing seam and press fit(mechanical joining such as, shown in U.S. Pat. No. 4,987,716)applications for roofing. In standing seam applications, the edges ofthe roofing materials are folded together and then soldered to form awater tight seal. The metal alloy inherently includes excellentsoldering characteristics. When the metal alloy is heated, it has thenecessary wetting properties to produce a tight water resistant seal. Asa result, the metal alloy acts as both a corrosive resistive coating anda soldering agent for standing seam roofing systems. The metal alloycoated can be also welded with standard solders. Typical solders containabout 50% tin and about 50% lead. The metal alloy has the addedadvantage of being able to be soldered with low or no-lead solders. Themetal alloy coated roofing materials also can be used in mechanicallyjoined roofing systems due to the malleability of the metal alloy.Mechanically joined systems form water tight seals by folding adjacentroof material edges together and subsequently applying a compressiveforce to the seam in excess of about 1,000 psi. Under these highpressures, the metal alloy plastically deforms within the seam andproduces a water tight seal.

[0282] The invention has been described with reference to preferred andalternate embodiments. Modifications and alterations will becomeapparent to those skilled in the art upon reading and understanding thedetailed discussion of the invention provided herein. This invention isintended to include all such modifications and alterations insofar asthey come within the scope of the present invention.

We claim:
 1. A method of producing a corrosion-resistant copper metalstrip comprising the steps of: (a) providing a copper metal strip from aroll of copper metal strip; (b) coating said copper metal strip with acorrosion resistant metal alloy, said corrosion resistant metal alloycomprising tin and zinc, said tin content plus said zinc contentconstituting a majority weight percent of the metal alloy, said metalalloy including at least about 15 weight percent tin; and, (c) forming aheat created intermetallic layer between said metal alloy coating andsaid copper metal strip by exposing said copper metal strip and saidmetal alloy to heat so as to enable at portion of said zinc in saidmetal alloy to migrate from said metal alloy and at least partiallycombine with said copper metal strip, said heat created intermetalliclayer includes at least about 60 weight percent copper plus zinc.
 2. Themethod as defined in claim 1, wherein said heat created intermetalliclayer has a thickness of up to about 10 microns.
 3. The method asdefined in claim 1, wherein said step of exposing said copper metalstrip and said metal alloy to heat is selected from the group consistingof applying molten metal alloy to said metal strip, flow heating saidmetal alloy on said metal strip, and combinations thereof.
 4. The methodas defined in claim 1, wherein said metal alloy comprises: Tin 15-90Zinc 10-85 Aluminum 0-2 Antimony 0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1Magnesium 0-2 Nickel 0-2 Titanium 0-1


5. The method as defined in claim 4, wherein said metal alloy comprises:Tin 40-60 Zinc 40-60 Aluminum 0-2 Antimony 0-2 Bismuth   0-1.7 Copper0-2 Iron 0-1 Lead   0-0.5 Magnesium 0-2 Nickel 0-2 Titanium 0-1


6. The method as defined in claim 5, wherein said metal alloy comprises:Tin 45-55 Zinc 45-55 Aluminum 0-2 Antimony 0-2 Bismuth   0-1.7 Boron  0-0.01 Cadmium   0-0.1 Carbon   0-0.5 Chromium   0-0.5 Copper 0-2 Iron0-1 Lead   0-0.5 Magnesium   0-0.4 Manganese   0-0.1 Molybdenum   0-0.1Nickel 0-2 Silicon   0-0.5 Titanium 0-1 Vanadium   0-0.1


7. The method as defined in claim 1, wherein said heat createdintermetallic layer includes at least about 75 weight percent copperplus zinc.
 8. The method as defined in claim 7, wherein said heatcreated intermetallic layer includes zinc and at least about 85 weightpercent copper plus zinc.
 9. The method as defined in claim 8, whereinsaid heat created intermetallic layer includes at least about 90 weightpercent copper plus zinc.
 10. The method as defined in claim 9, whereinsaid heat created intermetallic layer includes at least about 95 weightpercent copper plus zinc.
 11. The method as defined in claim 10, whereinsaid heat created intermetallic layer includes at least about 99 weightpercent copper plus zinc.
 12. The method as defined in claim 1, whereinsaid metal alloy coating includes less than or equal to the amount ofzinc in said metal alloy prior to coating on said copper metal strip.13. The method as defined in claim 12, wherein said metal alloy coatingincludes less than the amount of zinc in said metal alloy prior tocoating on said copper metal strip.
 14. A method of producing acorrosion-resistant metal strip comprising the steps of: (a) providing ametal strip from a roll of metal strip, said metal strip selected fromthe group consisting of carbon steel, stainless steel and aluminum; (b)applying a copper metal layer to said metal strip prior to coating saidmetal strip with a metal alloy; (c) coating said metal strip with acorrosion resistant metal alloy, said corrosion resistant metal alloycomprising tin and zinc, said tin content plus said zinc contentconstituting a majority weight percent of the metal alloy, said metalalloy including at least about 15 weight percent tin; and, (d) forming aheat created intermetallic layer between said metal alloy coating andsaid copper metal layer by exposing said copper metal layer and saidmetal alloy to heat so as to enable at portion of said zinc in saidmetal alloy to migrate from said metal alloy and at least partiallycombine with said copper metal layer, said heat created intermetalliclayer includes at least about 60 weight percent copper plus zinc. 15.The method as defined in claim 14, wherein said heat createdintermetallic layer has a thickness of up to about 10 microns.
 16. Themethod as defined in claim 14, wherein said step of exposing said coppermetal layer and said metal alloy to heat is selected from the groupconsisting of applying molten metal alloy to said metal layer, flowheating said metal alloy on said metal layer, and combinations thereof.17. The method as defined in claim 14, wherein said metal alloycomprises: Tin 15-90 Zinc 10-85 Aluminum 0-2 Antimony 0-2 Bismuth  0-1.7 Copper 0-2 Iron 0-1 Magnesium 0-2 Nickel 0-2 Titanium 0-1


18. The method as defined in claim 17, wherein said metal alloycomprises: Tin 40-60 Zinc 40-60 Aluminum 0-2 Antimony 0-2 Bismuth  0-1.7 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium 0-2 Nickel 0-2Titanium 0-1


19. The method as defined in claim 18, wherein said metal alloycomprises: Tin 45-55 Zinc 45-55 Aluminum 0-2 Antimony 0-2 Bismuth  0-1.7 Boron   0-0.01 Cadmium   0-0.1 Carbon   0-0.5 Chromium   0-0.5Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium   0-0.4 Manganese   0-0.1Molybdenum   0-0.1 Nickel 0-2 Silicon   0-0.5 Titanium 0-1 Vanadium  0-0.1


20. The method as defined in claim 14, wherein said heat createdintermetallic layer includes at least about 75 weight percent copperplus zinc.
 21. The method as defined in claim 20, wherein said heatcreated intermetallic layer includes at least about 85 weight percentcopper plus zinc.
 22. The method as defined in claim 14, wherein saidcopper metal layer is applied by a process selected from the groupconsisting of plating, immersion, brazening, adhesive, metal spraying,cladding, and combinations thereof.
 23. The method as defined in claim14, wherein said metal alloy coating includes less than or equal to theamount of zinc in said metal alloy prior to coating on said metal strip.24. The method as defined in claim 23, wherein said metal alloy coatingincludes less than the amount of zinc in said metal alloy prior tocoating on said metal strip.
 25. A method of forming acorrosion-resistant heat created intermetallic layer comprising thesteps of: (a) providing copper surface; (b) coating said copper surfacewith a corrosion resistant metal alloy, said corrosion resistant metalalloy comprising tin and zinc, said tin content plus said zinc contentconstituting a majority weight percent of the metal alloy, said metalalloy including at least about 15 weight percent tin; and, (c) exposingsaid copper surface and metal alloy to heat so as to at least partiallycause said zinc in said metal alloy to migrate from said metal alloy andat least partially combine with said copper surface to form a heatcreated intermetallic layer that includes at least about 60 weightpercent copper plus zinc.
 26. The method as defined in claim 25, whereinsaid heat created intermetallic layer has a thickness of up to about 10microns.
 27. The method as defined in claim 25, wherein said step ofexposing said copper surface and metal alloy to heat includes theapplication of molten metal alloy to said copper surface, flow heatingsaid metal alloy which is coated on said copper surface, andcombinations thereof.
 28. The method as defined in claim 25, whereinsaid metal alloy comprises: Tin 15-90 Zinc 10-85 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1 Magnesium 0-2 Nickel 0-2Titanium 0-1


29. The method as defined in claim 28, wherein said metal alloycomprises: Tin 40-60 Zinc 40-60 Aluminum 0-2 Antimony 0-2 Bismuth  0-1.7 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium 0-2 Nickel 0-2Titanium 0-1


30. The method as defined in claim 29, wherein said metal alloycomprises: Tin 45-55 Zinc 45-55 Aluminum 0-2 Antimony 0-2 Bismuth  0-1.7 Boron   0-0.01 Cadmium   0-0.1 Carbon   0-0.5 Chromium   0-0.5Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium   0-0.4 Manganese   0-0.1Molybdenum   0-0.1 Nickel 0-2 Silicon   0-0.5 Titanium 0-1 Vanadium  0-0.1


31. The method as defined in claim 25, wherein said heat createdintermetallic layer includes at least about 75 weight percent copperplus zinc.
 32. The method as defined in claim 31, wherein said heatcreated intermetallic layer includes at least about 85 weight percentcopper plus zinc.
 33. The method as defined in claim 32, wherein saidheat created intermetallic layer includes at least about 90 weightpercent copper plus zinc.
 34. The method as defined in claim 33, whereinsaid heat created intermetallic layer includes at least about 95 weightpercent copper plus zinc.
 35. The method as defined in claim 34, whereinsaid heat created intermetallic layer includes at least about 99 weightpercent copper plus zinc.
 36. The method as defined in claim 25, whereinsaid metal alloy coating includes less than or equal to the amount ofzinc in said metal alloy prior to exposing said metal alloy to saidcopper surface.
 37. The method as defined in claim 36, wherein saidmetal alloy coating includes less than the amount of zinc in said metalalloy prior to exposing said metal alloy to said copper surface.
 38. Acorrosion-resistant metal strip comprising metal strip coated with acorrosion resistant metal alloy and a heat created intermetallic layerbetween said metal alloy coating and said metal strip, said metal stripselected from the group consisting of copper strip, carbon steel strip,stainless steel strip, and aluminum strip, said corrosion resistantmetal alloy comprising tin and zinc, said tin content plus said zinccontent constituting a majority weight percent of the metal alloy, saidmetal alloy including at least about 15 weight percent tin and at leastabout 5 weight percent zinc, said heat created intermetallic layerincluding at least about 60 weight percent copper plus zinc.
 39. Thecorrosion-resistant metal strip as defined in claim 38, wherein saidheat created intermetallic layer has a thickness of up to about 10microns.
 40. The corrosion-resistant metal strip as defined in claim 38,wherein said metal alloy comprises: Tin 15-90 Zinc 10-85 Aluminum 0-2Antimony 0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1 Magnesium 0-2 Nickel0-2 Titanium 0-1


41. The corrosion-resistant metal strip as defined in claim 40, whereinsaid metal alloy comprises: Tin 40-60 Zinc 40-60 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium 0-2Nickel 0-2 Titanium 0-1


42. The corrosion-resistant metal strip as defined in claim 41, whereinsaid metal alloy comprises: Tin 45-55 Zinc 45-55 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Boron   0-0.01 Cadmium   0-0.1 Carbon   0-0.5Chromium   0-0.5 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium   0-0.4Manganese   0-0.1 Molybdenum   0-0.1 Nickel 0-2 Silicon   0-0.5 Titanium0-1 Vanadium   0-0.1


43. The corrosion-resistant metal strip as defined in claim 38, whereinsaid heat created intermetallic layer includes at least about 75 weightpercent copper plus zinc.
 44. The corrosion-resistant metal strip asdefined in claim 43, wherein said heat created intermetallic layerincludes at least about 85 weight percent copper plus zinc.
 45. Thecorrosion-resistant metal strip as defined in claim 44, wherein saidheat created intermetallic layer includes at least about 90 weightpercent copper plus zinc.
 46. The corrosion-resistant metal strip asdefined in claim 45, wherein said heat created intermetallic layerincludes at least about 95 weight percent copper plus zinc.
 47. Thecorrosion-resistant metal strip as defined in claim 46, wherein saidheat created intermetallic layer includes at least about 99 weightpercent copper plus zinc.
 48. The corrosion-resistant metal strip asdefined in claim 38, wherein said metal alloy coating includes less thanor equal to the amount of zinc in said metal alloy prior to coating onsaid metal strip.
 49. The corrosion-resistant metal strip as defined inclaim 48, wherein said metal alloy coating includes less than the amountof zinc in said metal alloy prior to coating on said metal strip.
 50. Acorrosion-resistant petroleum receptacle comprising at least one shellmember coated with a corrosion resistant metal alloy, said shell memberincluding a strip formed at least partially from carbon steel, stainlesssteel, aluminum, or titanium, said strip having a copper or copper alloysurface layer that is coated with a corrosion resistant metal alloy andhaving a heat created intermetallic layer between said metal alloycoating and said copper or copper alloy layer, said corrosion resistantmetal alloy comprising tin and zinc, said tin content plus said zinccontent constituting a majority weight percent of the metal alloy, saidmetal alloy including at least about 15 weight percent tin, said heatcreated intermetallic layer including at least about 60 weight percentcopper plus zinc.
 51. The corrosion-resistant petroleum receptacle asdefined in claim 50, wherein said heat created intermetallic layer has athickness of up to about 10 microns.
 52. The corrosion-resistantpetroleum receptacle as defined in claim 50, wherein said metal alloycomprises: Tin 15-90 Zinc 10-85 Aluminum 0-2 Antimony 0-2 Bismuth  0-1.7 Copper 0-2 Iron 0-1 Magnesium 0-2 Nickel 0-2 Titanium 0-1


53. The corrosion-resistant petroleum receptacle as defined in claim 52,wherein said metal alloy comprises: Tin 40-60 Zinc 40-60 Aluminum 0-2Antimony 0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium0-2 Nickel 0-2 Titanium 0-1


54. The corrosion-resistant petroleum receptacle as defined in claim 53,wherein said metal alloy comprises: Tin 45-55 Zinc 45-55 Aluminum 0-2Antimony 0-2 Bismuth   0-1.7 Boron   0-0.01 Cadmium   0-0.1 Carbon  0-0.5 Chromium   0-0.5 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium  0-0.4 Manganese   0-0.1 Molybdenum   0-0.1 Nickel 0-2 Silicon   0-0.5Titanium 0-1 Vanadium   0-0.1


55. The corrosion-resistant petroleum receptacle as defined in claim 50,wherein said heat created intermetallic layer includes at least about 75weight percent copper plus zinc.
 56. The corrosion-resistant petroleumreceptacle as defined in claim 55, wherein said heat createdintermetallic layer includes at least about 85 weight percent copperplus zinc.
 57. The corrosion-resistant petroleum receptacle as definedin claim 56, wherein said heat created intermetallic layer includes atleast about 90 weight percent copper plus zinc.
 58. Thecorrosion-resistant petroleum receptacle as defined in claim 57, whereinsaid heat created intermetallic layer includes at least about 95 weightpercent copper plus zinc.
 59. The corrosion-resistant petroleumreceptacle as defined in claim 58, wherein said heat createdintermetallic layer includes at least about 99 weight percent copperplus zinc.
 60. The corrosion-resistant petroleum receptacle as definedin claim 50, wherein said metal alloy coating includes less than theamount of zinc in said metal alloy prior to coating on said metal strip.61. A corrosion-resistant coated base metal comprising a base metalhaving a copper surface coated with a corrosion resistant metal alloyand an intermetallic layer at least partially between said base metaland said corrosion resistant metal alloy, said base metal including acarbon steel, stainless steel, aluminum, or titanium, said corrosionresistant metal alloy comprising tin and zinc, said tin content plussaid zinc content constituting a majority weight percent of the metalalloy, said metal alloy including at least about 15 weight percent tin,said heat created intermetallic layer including at least about 60 weightpercent copper plus zinc.
 61. The corrosion-resistant coated base metalas defined in claim 60, wherein said intermetallic layer has a thicknessof up to about 10 microns.
 62. The corrosion-resistant coated base metalas defined in claim 60, wherein said metal alloy comprises: Tin 15-90Zinc 10-85 Aluminum 0-2 Antimony 0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1Magnesium 0-2 Nickel 0-2 Titanium 0-1


63. The corrosion-resistant coated base metal defined in claim 62,wherein said metal alloy comprises: Tin 40-60 Zinc 40-60 Aluminum 0-2Antimony 0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium0-2 Nickel 0-2 Titanium 0-1


64. The corrosion-resistant coated base metal as defined in claim 61,wherein said heat created intermetallic layer includes at least about 75weight percent copper plus zinc.